The future of single-use plastics in life science: Sterile printing of PLA reduces greenhouse gas emissions by 80% and enables carbon neutrality

Abstract

The European Union’s Green Deal emphasizes life science and biotechnology as key drivers for achieving a circular economy. However, the prevalent use of non-sustainable single-use plastics derived from petrochemical sources in life science research and development contradicts this ecological goal. This study presents a viable alternative through on-site sterile 3D printing of single-use plastics using poly(lactic acid) (PLA). The sterile printing of PLA demonstrates a substantial reduction in CO${}_{\mathrm{2eq}}$ emissions per shake flask, decreasing from 260 g CO${}_{\mathrm{2eq}}$ to 145 g CO${}_{\mathrm{2eq}}$. Suitability for cell culture was demonstrated for sterile printed PLA, autoclaved high-temperature PLA and for suspension cell cultures in shake flasks using CHO and insect cells as well as adherent Vero cell cultures in cell culture wells. Further optimization of sustainable shake flasks is achieved by utilizing recycled PLA, resulting in a remarkable reduction to 73 g CO${}_{\mathrm{2eq}}$, constituting a 72% decrease in CO${}_{\mathrm{2eq}}$ emissions compared to conventional single-use plastics. Moreover, by employing geometric optimization to minimize material usage, emissions can be further reduced to 44 g CO${}_{\mathrm{2eq}}$, representing an 83% reduction in CO${}_{\mathrm{2eq}}$ emissions. Anticipated advancements in PLA production suggest future carbon net negative PLA production, potentially achieving zero carbon emissions for single-use plastics using PLA. The exceptionally cost-effective nature of 3D printed single-use plastics, coupled with negligible capital costs for implementation, positions sterile 3D printing as a practical solution aligned with the 2030 Green Deal goals. Moreover, ongoing improvements in bioplastic production underscore the feasibility of meeting the 2050 targets of carbon neutrality for single-use plastics in life science research and development.