{"691214":{"#nid":"691214","#data":{"type":"news","title":"Rapid Testing Offers Path to More Sustainable Material Choices","body":[{"value":"\u003Cp\u003E\u003Cem\u003E-Written by Seungho Lee\u003C\/em\u003E\u003C\/p\u003E\u003Cp\u003ERecycled materials promise a cleaner future, but recycled content alone does not necessarily make a product sustainable. At Georgia Tech\u2019s Daedalus Lab, assistant professor, National Science Foundation CAREER Award recipient, and Brook Byers Institute for Sustainable Systems Faculty Fellow Christos Athanasiou and postdoctoral researcher Danqi Sun are working to provide greater certainty to designers and engineers by rethinking how materials are tested for their fracture characteristics. Their article in \u003Ca href=\u0022https:\/\/www.science.org\/doi\/10.1126\/sciadv.aeh0456\u0022\u003E\u003Cem\u003EScience Advances\u003C\/em\u003E\u003C\/a\u003E details a new testing protocol that reduces cost, increases speed, and simulates real-world conditions.\u003C\/p\u003E\u003Cp\u003EMaterials shape nearly every part of modern life, from packaging and consumer products to bridges and medical devices. Choosing the right material involves balancing durability, cost, manufacturability, and environmental impact. Yet those decisions are not always guided by a clear understanding of how materials age and fail under real-world conditions, especially for recycled materials like plastics.\u003C\/p\u003E\u003Cp\u003EOne way that materials frequently fail is by cracking. A small crack can begin almost invisibly. Over time, it can spread from regular wear and tear and exposure to common environmental factors like moisture, temperature fluctuations, or even dirt. Eventually, the crack expands, and the part fails. Engineers have studied fracture for more than a century, but connecting the science of cracking to practical decisions about sustainability remains a major challenge.\u003C\/p\u003E\u003Cp\u003EThe characteristics of recycled plastics often vary from those of the same material in unrecycled, or virgin, form. Products made from recycled plastics may be sold with sustainability claims under the assumption that they will perform as if they were made with virgin material. However, premature failure requiring repair or replacement can quickly change the sustainability equation as well as the acceptance of recycled materials by manufacturers and consumers.\u003C\/p\u003E\u003Ch3\u003E\u003Cstrong\u003EBeyond Conventional Fracture Testing\u003C\/strong\u003E\u003C\/h3\u003E\u003Cp\u003EMaterials rarely fail due to a single factor. They may be exposed to several factors simultaneously, such as mechanical loading, chemical environments, temperature changes, moisture, and time. Traditional fracture protocols test one specimen at a time under carefully controlled laboratory conditions, which bear little resemblance to the real world. To move beyond this limitation, Sun developed an in-situ, high-throughput platform capable of studying how materials degrade and fail under more realistic conditions.\u003C\/p\u003E\u003Cp\u003EThe platform changes conventional fracture testing in three important ways. First, it can test multiple specimens simultaneously rather than one at a time. By monitoring samples in parallel, testing time can be reduced by more than 60%. Second, it allows materials to be tested in realistic environments. In this study, researchers examined virgin and recycled plastics in alkaline environments that resemble conditions encountered in applications like landfill liner membranes and geotextiles. Third, the platform incorporates an imaging technique known as photoelasticity, which reveals the formation of stress fields that form around the origin of a newly developing crack. This allows researchers to see cracks develop earlier than before, giving them a clearer picture of the forces that drive crack growth.\u003C\/p\u003E\u003Cp\u003EThe researchers have made the technology available for licensing through Georgia Tech\u2019s Office of Technology Licensing. \u201cOur goal was to make fracture testing not only faster but also more informative,\u201d Sun said. \u201cBy combining high-throughput testing, realistic environments, and full-field stress imaging, we can better understand how materials fail under conditions closer to real-world applications.\u201d\u003C\/p\u003E\u003Ch3\u003E\u003Cstrong\u003EAn Honest View of Sustainability\u003C\/strong\u003E\u003C\/h3\u003E\u003Cp\u003ERecycled plastics are often viewed as a greener choice. But according to the study, it\u2019s not always so straightforward. If a recycled product fails prematurely and needs to be replaced frequently, its environmental and economic costs can increase despite its recycled content. As Athanasiou puts it, \u201cFailing materials don\u2019t just break products. They can break sustainability promises.\u201d\u003C\/p\u003E\u003Cp\u003EFor example, comparing virgin polyethylene terephthalate (PET) with recycled PET (rPET) in applications such as landfill geotextiles, the researchers discovered that rPET showed lower resistance to environmental stressors, particularly in alkaline conditions over a pH of 9. In this application, specifying rPET over virgin PET would likely eliminate all of the presumed economic and environmental advantages of using a recycled material.\u003C\/p\u003E\u003Cp\u003E\u201cRecycling is essential, but recycled content alone does not tell the full story. If a material fails too soon, the environmental benefits can disappear,\u201d Athanasiou said.\u003C\/p\u003E\u003Ch3\u003E\u003Cstrong\u003EFrom Cracks to Circularity\u003C\/strong\u003E\u003C\/h3\u003E\u003Cp\u003EFor the researchers, the significance of the work extends beyond recycled plastics. The broader goal is to provide a fast, affordable, and realistic platform for evaluating the sustainability of any material choice. Because current testing protocols are costly, not widely available, and limited in the information they yield, engineers, manufacturers, and policymakers often have little choice but to continue to specify non-recycled materials because they will perform as expected. Having cheap and accurate data on recycled materials will help to accelerate their adoption because matching the engineering properties of recycled materials to their most appropriate applications will become more obvious.\u003C\/p\u003E\u003Cp\u003EThe researchers also hope to expand the platform to simulate even more complex environments and apply it to a wider range of materials. Because the system generates large amounts of detailed data, it may enable opportunities to use computational modeling or artificial intelligence to digitally simulate mechanical testing, driving down costs and expanding availability even more.\u003C\/p\u003E\u003Cp\u003EThe larger vision is a future in which sustainability is judged not by labels or assumptions, but by evidence for how a material performs, how long it lasts, how it fails, and what it costs society and the environment over its full lifetime.\u003C\/p\u003E\u003Cp\u003EPlease visit the Daedalus Lab YouTube channel to see an explainer video about this new testing protocol: \u003Ca href=\u0022https:\/\/www.youtube.com\/watch?v=zmRhiRIiAkQ\u0022\u003Ehttps:\/\/youtube.com\/watch?v=zmRhiRIiAkQ\u003C\/a\u003E\u003C\/p\u003E\u003Cp\u003ERead the paper here: \u003Ca href=\u0022https:\/\/www.science.org\/doi\/10.1126\/sciadv.aeh0456\u0022\u003Ehttps:\/\/www.science.org\/doi\/10.1126\/sciadv.aeh0456\u003C\/a\u003E\u003C\/p\u003E\u003Cp\u003EThis research was supported by the National Science Foundation CAREER Award No. 2338508.\u003C\/p\u003E","summary":"","format":"limited_html"}],"field_subtitle":"","field_summary":[{"value":"\u003Cp\u003EChoosing the right materials for manufacturing products involves balancing durability, cost, manufacturability, and environmental impact. Yet those decisions are not always guided by a clear understanding of how materials age and fail under real-world conditions, especially for recycled materials like plastics.\u003C\/p\u003E","format":"limited_html"}],"field_summary_sentence":[{"value":"At Georgia Tech\u2019s Daedalus Lab, Christos Athanasiou and postdoctoral researcher Danqi Sun are working to provide greater certainty to designers and engineers by rethinking how materials are tested for their fracture characteristics. "}],"uid":"27338","created_gmt":"2026-07-22 20:31:53","changed_gmt":"2026-07-24 18:22:28","author":"Brent Verrill","boilerplate_text":"","field_publication":"","field_article_url":"","location":"Atlanta, GA","dateline":{"date":"2026-07-24T00:00:00-04:00","iso_date":"2026-07-24T00:00:00-04:00","tz":"America\/New_York"},"extras":[],"hg_media":{"680664":{"id":"680664","type":"image","title":"Athanasiou_rPET_Fracture_Testing_Screencap.jpg","body":null,"created":"1784836559","gmt_created":"2026-07-23 19:55:59","changed":"1784836559","gmt_changed":"2026-07-23 19:55:59","alt":"Side-by-side scientific visualization comparing in-situ photoelasticity and modeled stress field evolution during fracture testing of a transparent material. The left panel shows a rectangular specimen with rainbow-colored stress patterns radiating from a crack tip near the center-right edge, while the right panel shows a corresponding color-coded stress map with blue, green, yellow, and red regions indicating increasing stress concentration around the crack tip. Labels at the top identify the two methods.","file":{"fid":"264955","name":"Athanasiou_rPET_Fracture_Testing_Screencap.jpg","image_path":"\/sites\/default\/files\/2026\/07\/23\/Athanasiou_rPET_Fracture_Testing_Screencap.jpg","image_full_path":"http:\/\/hg.gatech.edu\/\/sites\/default\/files\/2026\/07\/23\/Athanasiou_rPET_Fracture_Testing_Screencap.jpg","mime":"image\/jpeg","size":75075,"path_740":"http:\/\/hg.gatech.edu\/sites\/default\/files\/styles\/740xx_scale\/public\/2026\/07\/23\/Athanasiou_rPET_Fracture_Testing_Screencap.jpg?itok=35tzJwYR"}}},"media_ids":["680664"],"groups":[{"id":"244191","name":"Brook Byers Institute for Sustainable Systems"},{"id":"1188","name":"Research Horizons"},{"id":"660398","name":"Sustainability Hub"}],"categories":[{"id":"136","name":"Aerospace"},{"id":"194606","name":"Artificial Intelligence"},{"id":"145","name":"Engineering"},{"id":"154","name":"Environment"},{"id":"179356","name":"Industrial Design"},{"id":"194685","name":"Manufacturing"},{"id":"135","name":"Research"},{"id":"194836","name":"Sustainability"}],"keywords":[{"id":"192170","name":"Christos Athanasiou"},{"id":"178818","name":"circular economy"},{"id":"188360","name":"go-bbiss"},{"id":"194823","name":"plastic recycling"}],"core_research_areas":[{"id":"194566","name":"Sustainable Systems"}],"news_room_topics":[],"event_categories":[],"invited_audience":[],"affiliations":[],"classification":[],"areas_of_expertise":[],"news_and_recent_appearances":[],"phone":[],"contact":[{"value":"\u003Cp\u003E\u003Ca href=\u0022mailto:brent.verrill@research.gatech.edu\u0022\u003EBrent Verrill\u003C\/a\u003E, Research Communication Manager, BBISS\u003C\/p\u003E","format":"limited_html"}],"email":["brent.verrill@research.gatech.edu"],"slides":[],"orientation":[],"userdata":""}}}