Progress in bioplastics blends, compatibilization, modifications, and AI-driven innovations for material applications

Many bioplastics offer potential advantages over petroleum-based plastics, such as renewability, improved sustainability, and, in some cases, biodegradability or lower toxicity. However, in most cases, their limited mechanical performance, processing stability, or higher production costs hinder widespread adoption. Blending is a key strategy to overcome these limitations; however, the inherent immiscibility of most biopolymers leads to challenges like coarse morphology and poor interfacial adhesion. This review aims to provide an in-depth analysis of bioplastic blends by examining the fundamental principles (thermodynamic interactions, process kinematics, and morphology development) that control their behavior. It critically evaluates a broad spectrum of compatibilization strategies that span non-reactive and reactive methods and those utilizing nanofillers, aimed at stabilizing blend microstructures and enhancing material performance. A novel aspect of this work is its integration of these material science concepts with important end-of-life considerations, including biodegradability and recyclability challenges. Furthermore, it highlights the transformative role of artificial intelligence (AI) and machine learning (ML) as novel instruments for accelerating the design and optimization of next-generation bioplastic formulations. Overall, this review concludes that unlocking the full potential of bioplastics for high-performance industrial applications necessitates a holistic approach that integrates tailored blending strategies with advanced computational design, thus paving the way for the realization of a circular bioeconomy.