Sustainable and Microplastic-Free PHA-based Materials for the Next Generation of Dental Appliances

Recipient organisation

PHAST LIMITED

Project reference

10189639

Funder

Innovate UK

Programme

Innovate UK Growth Catalyst – Investor Partnerships Round 2

Award value

£494,721

Project dates

1 Jul 2026 – 30 Jun 2028

Imported sector

Advanced Manufacturing Lvl3

Postcode area

S (S1 4DP)

Project status

Live

Source data quality

Description present in snapshot

Official project description

This project will explore and demonstrate new sustainable materials for use in removable dental appliances (aligners, retainers, bleaching trays, and sleep-apnea splints), an essential set of products used daily by millions of people in the UK and worldwide. Current dental appliances are made from multiple petrochemical-based plastics such as polyethylene and polyurethane. These materials provide the necessary flexibility, comfort and wear resistance, but generate significant environmental impacts with no sustainable end-of-life options, and release microplastic in the body. The aim of this project is to create the first tailored medical-grade polyhydroxyalkanoate (PHA) formulations suitable for use in dental appliances. PHAs are an emerging family of biopolymers produced from renewable resources through bacterial fermentation, offering significantly lower life-cycle carbon emissions than conventional plastics. They also have the potential for improved end-of-life performance, including home and industrial compostability. The project will focus on developing and testing bespoke PHA materials with adequate mechanical, thermal, clarity, and stability properties for the proposed applications. Moreover, the project will ensure validation of medical safety and environmental claims through testing according to industrial standards (ISOs, ENs, ASTMs). To achieve this, PHAsT Ltd. will collaborate with NAMSA, a CRO specialized in medical device testing and regulatory pathways, and the Polymer Micro and Nano Technology centre at the University of Bradford, which brings expertise in medical polymer compounding and processing. Together, the partners will evaluate how these new materials can be processed, extruded and thermoformed into prototypes that meet real performance requirements. The outcomes of the industrial research project will include end products material formulation R&D, testing, pilot-scale end products manufacturing, safety and environmental certifications, processing guidelines and an LCA assessment of environmental benefits. These results will help determine whether sustainable PHA-based materials can replace fossil-derived plastics in removable dental appliances and support commercial adoption. If successful, this innovation could contribute to reducing the carbon footprint of dental products up to 80%, support the UK's transition to more sustainable materials, and provide new opportunities for environmentally responsible manufacturing in the healthcare sector. This aligns with national and NHS goals for net-zero emissions and resource efficiency, while supporting improved medical product sustainability without compromising patient comfort or safety.