Across dental technology, we manufacture products designed to last weeks, or at best a few years, using materials designed to last centuries. We have normalised the waste that comes with it, with almost 80–90% of material lost during the thermoforming process. And consider this: 100% of the material used for orthodontic aligners is discarded within just a few weeks.
A new approach to materials is starting to change how dental products are made.
Phast—Polyhydroxyalkanoate Sustainable Technology—is a University of Sheffield spin-out developing a new class of bioplastics produced through bacterial fermentation.
This is not “less harmful” plastic. It is not simply “recyclable” plastic. It is plastic designed from the outset to behave differently at end of life.
Fully biodegradable. No microplastics. Compostable in as little as 3 to 4 months. Gone by design.
More importantly, these materials are being developed to replace what labs and manufacturers already use today, without changing how products are made.
Funding Momentum
Phast has secured £500,000 from members of Sheffield Angels and Cambridge Angels, unlocking a further £500,000 in matched funding through an Innovate UK Investor Partnership grant—a £1 million milestone that accelerates the journey from innovation to commercial reality.
CEO Andrea Mele explains:
“Phast has been awarded an Innovate UK Investor Partnership grant of £500,000 alongside private investment. This funding allows us to accelerate R&D and bring more of that work in-house as we move toward commercialisation.”
That acceleration matters. This is not a theoretical process. The material is already being used and trialled within medical applications, demonstrating that performance and biodegradability no longer have to be a tradeoff.
In practice, that means working closely with labs and manufacturers—testing, refining, and adjusting materials until they perform exactly as needed in real-world applications.
The Waste Nobody Talks About
When you look at our industry, the scale of the problem becomes difficult to ignore.
In thermoforming alone, most of the material is wasted during production. Offcuts, trimming, and inefficiencies are simply accepted, and in many cases, recycling isn’t even an option.
Aligners go further. Every aligner ever produced is designed to be discarded after use. Millions every year, manufactured, worn, and thrown away within weeks.
Add to that the rapid expansion of 3D printing, where model production is scaling quickly using materials that currently have no meaningful end-of-life solution.
We have optimised everything, except what happens afterwards.
Until now, there hasn’t been a realistic alternative that works in these applications at scale.
A Material That Changes What Happens Next
Phast is challenging the way dental materials have traditionally been made.
Imagine thermoforming where waste is no longer waste.
Where used aligners don’t accumulate, they break down safely after use.
Where 3D printed models, once used, can be composted rather than discarded.
Not managed. Not stored. Not landfilled. Gone.
What the Industry Is Saying
That shift is already gaining attention across both investors and the dental industry.
Andy Holliday – Sheffield Angels Member:
“We’re really excited about this investment. Phast generated strong interest across both Sheffield Angels and Cambridge Angels, and it’s great to be collaborating on this one. Reducing waste and finding better alternatives to traditional plastics is a huge challenge, and what they’re building has the potential to make a real difference.A big part of our decision was the team—they’re already having the right conversations in industry, which gives us real confidence in what they’re building.”
Matt Everatt FCGDent FOTA — Dental Technician for over 30 years:
“Having spent my career working with these materials, you see first-hand how much waste is built into the system—not just in manufacturing, but during production, patient use, and at end of life. We still don’t fully understand the long-term impact of microplastics in the oral environment, and that uncertainty matters. What Phast offers is a genuine alternative—one that has the potential to change not just what we use, but how we think about manufacturing altogether.”
Looking Ahead
What looks like innovation today quickly becomes expectation tomorrow.
This is not just a funding announcement, it is a signal that the materials we have relied on for decades are no longer inevitable. The scale of waste we accept today is no longer justifiable or a necessary part of the process.
For labs and manufacturers, the conversation is starting to shift, from awareness to action. What could you replace, and where do you start?
The future of dental manufacturing may look very different, very quickly.
The question is no longer whether materials like this will reach our industry.
It is how quickly your lab will start working with them.
Frequently Asked Questions
- What exactly is PHA?
PHA is a family of polymers produced through bacterial fermentation using renewable carbon sources. From a user perspective, it behaves like a conventional plastic during use. At end of life, it can break down into natural byproducts without forming microplastics. - Can it really replace the materials we’re using today?
In many applications, yes. Each product has specific requirements such as clarity, flexibility, or strength. We start with your current material and application, then adjust the PHA formulation to match those requirements. This is usually an iterative process. We test, refine, and adjust until the material performs the way you need it to. Once it is right, it can be used in place of your existing material. This approach applies across dental, medical, and personal care products where performance and end-of-life impact both matter. - Will we need to change our manufacturing process?
In most cases, no. PHA can be processed using standard methods such as thermoforming, injection molding, and extrusion. Processing conditions may need to be adjusted, but the overall workflow and equipment typically remain the same. We work with you during this stage to make sure the material runs correctly in your process. - What happens to the material after it’s used?
PHA is designed to break down through natural biological processes. In appropriate conditions, it can be composted and will degrade into carbon dioxide, water, and biomass. It does not persist as microplastics in the environment. - Why is this relevant for dental products and beyond?
Dental products are used in the mouth and then discarded after a short period of time. That means material performance during use and material behavior after disposal both matter. PHA allows manufacturers to maintain required performance while improving what happens at end of life.The same applies to other products such as medical devices and personal care items, where materials come into direct contact with the body and are frequently disposed of after use. - What does it look like to work with Phast?
We do not just supply raw material. We work with your team to develop a formulation that fits your product. That usually means starting with a prototype, testing it, and making adjustments based on performance. For example, one version may be too rigid, another may not have the right clarity. We refine the material step by step until it performs correctly. The goal is to deliver a material that you can use in your existing process, without needing to figure it out on your own. For more information, contact [email protected].