Chemists Unveil Innovative Method to Transform Everyday Plastics

Chemists at the University of Florida have developed a groundbreaking technique to create advanced porous materials from common plastics, presenting new possibilities for various industries including electronics and battery manufacturing. This innovative method focuses on the removal of material, rather than the addition of new substances, enabling the transformation of everyday plastics into highly functional materials.

Brent Sumerlin, Ph.D., a professor of chemistry and senior author of the study, likened the process to sculpting. “It’s like what a sculptor might do with stone, where you gradually subtract more and more until you have what you want,” he explained. This approach allows for the creation of tiny pores within the material, which could not be achieved by traditional methods.

From Plastics to Pores: The Process

The research team utilized the breakdown of plastics—a pivotal aspect of enhancing plastic recycling. By understanding that different plastics decompose at varying temperatures, Sumerlin’s lab was able to exploit these differences to forge new materials. The combination of Plexiglass and Styrofoam, typically resistant to mixing, was subjected to precise heating. As a result, the components resembling Plexiglass evaporated, leaving behind polystyrene and creating trillions of minuscule gaps, even smaller than a virus.

Despite weighing only one gram, a sample of this newly created material boasts a surface area equivalent to a full-sized tennis court. This extensive surface area is crucial for advanced manufacturing processes, particularly in applications requiring efficient separation and filtration.

Potential Applications and Impact

The porous materials produced through this technique are in high demand for various applications. They can function as natural filters for contaminated water and enhance the performance of batteries by serving as high-efficiency membranes. Sumerlin noted that the method could lead to significant advancements in energy separation processes, which are essential for numerous industries.

“The new way to craft these porous filters, out of little more than plastic, may serve many different applications,” Sumerlin remarked. He has also filed a patent application to protect this novel technique, highlighting its potential impact on both recycling efforts and the manufacturing sector.

The findings of this research were published on November 4, 2025, in the journal ACS Central Science, showcasing how fundamental research can yield innovative solutions across diverse fields. Sumerlin emphasized the importance of such interdisciplinary advancements, stating, “This just shows how basic research in one area can inform new applications in a completely different area.”

As industries continue to seek sustainable materials and efficient processes, this innovative technique represents a promising step forward in the quest to repurpose everyday plastics into valuable resources.