Bernastic

Stronger. Lighter. Greener.

Bernastic™ is a groundbreaking polymer that transforms apparel waste and recycled plastic into high-performance pellets for manufacturing. Engineered with a patent-pending process, Bernastic combines recycled HDPE with pre- and post-consumer cotton waste to outperform traditional plastics—delivering 3x the strength and 10% less weight than pure HDPE. From pallets to piping to 3D printing, Bernastic not only diverts textile and plastic waste from landfills, but also offers a scalable solution for sustainable production across global supply chains

Key Advantages

  • Upcycled Blend

    Bernastic transforms two of the world’s largest waste streams—cotton textiles and plastic—into a single sustainable material. This circular innovation reduces landfill use and gives discarded garments a second life in manufacturing

  • Superior Strength

    Bernastic outperforms traditional HDPE by a wide margin. It is 3× stronger and has 20% higher tensile strength. It’s tough enough for industrial use, strong enough for structural products, and durable enough to replace virgin plastic.

  • Built for Efficiency

    Bernastic is 10% lighter than conventional plastics, helping reduce transportation weight, fuel usage, and material costs—especially in shipping and logistics where every pound matters. The weight savings also make it easier to handle during manufacturing and assembly, improving workflow and worker efficiency.

  • 3D Printable & Moldable

    Unlike pure HDPE, Bernastic can be extruded into filament and used in 3D printing. It supports detailed, durable prints while maintaining a sustainable materials profile, making it ideal for designers, engineers, and entrepreneurs seeking high-performance, eco-conscious solutions.

  • Eco-Friendly Alternative

    By replacing deforestation-heavy wood and virgin plastics, Bernastic enables brands to cut emissions, reduce waste, and move toward more circular manufacturing practices. It’s a practical way for companies to meet ESG goals without compromising on performance or cost.

  • Clean, Odor-Free Processing

    Engineered with performance and practicality in mind, Bernastic is clean, consistent, and production-ready—suited for both industrial and consumer-grade applications. Optimized with performance additives, it meets the visual, tactile, and sensory standards required for high-quality finished products.

What’s inside

Retail & Logistics

Maybe you're looking to replace wooden pallets with something lighter, stronger, and sustainable. Bernastic offers a smarter solution for shipping without the carbon cost of deforestation.

Home & Industrial Goods

Maybe you want to turn a hobby into something more. Maybe you want to create furniture, piping, or hangers from a material that's as responsible as it is reliable.

Maker & 3D Printing Market

Maybe you want to prototype faster. Maybe you want to launch a product line. Bernastic is 3D printable, strong, and sustainably sourced—perfect for creators and small-scale manufacturers.

Frequently asked questions

  • Bernastic is made from a proprietary blend of recycled HDPE (high-density polyethylene) and pre- and post-consumer cotton textile waste. This unique formula allows it to leverage two waste streams—plastic and cotton—into a high-performance material that’s both durable and environmentally responsible.

  • Compared to virgin HDPE, Bernastic is 3× stronger, 10% lighter, and has 20% greater tensile strength. It’s also designed to be more sustainable—reducing the need for virgin plastic and helping brands meet environmental goals without sacrificing performance.

  • Bernastic is injection moldable and 3D printable, making it suitable for a wide range of products—from pallets, hangers, and piping to furniture, auto components, and custom 3D-printed goods. It’s built for versatility across both industrial and consumer applications.

  • We are currently working with manufacturers, material suppliers, and early adopters. If you're interested in sampling, licensing, or piloting Bernastic for your products, reach out to us directly through our contact form or email us at michael@bernastic.com

  • Bernastic tackles two major environmental issues—textile waste and plastic pollution—by turning them into one high-performance material. By reducing reliance on virgin plastic and preventing cotton waste from entering landfills, it helps manufacturers lower emissions and meet sustainability goals without compromising on strength or functionality.

  • Yes. Bernastic is engineered for end-use quality, with optimized additives to ensure a clean, consistent finish. It's free of residual odors, visually stable, and performs well in both functional and aesthetic applications—making it ideal for items like furniture, home goods, and retail fixtures.