The structures they created greatly reduced the variability of mechanical properties typically found in recycled plastic. Their product also maintained the performance of the original plastic materials.

The researchers said their bio-inspired design could help cut manufacturing costs of virgin packaging materials by nearly 50% and offer potential savings of hundreds of millions of dollars. And, because less than 10% of the 350 million tons of plastics produced each year is effectively recycled, the Georgia Tech approach could keep more plastic out of landfills.

Aerospace engineering assistant professor Christos Athanasiou led the study, which was published in the journal Proceedings of the National Academy of Sciences (PNAS). 

Read the Q&A of the findings, and see a video of the testing, on the College of Engineering website.