Reviewed by Frances BriggsJun 18 2025
A new study published in Nano-Micro Letters introduces a cost-effective upcycling method that turns disposable face masks into high-performance nanocomposite materials, offering environmental and economic benefits.
Image Credit: Kiefer Photography/Shutterstock.com
Disposable face masks, used on a large scale to combat the spread of COVID-19 at the height of the pandemic, have since become a significant contributor to environmental pollution and human health hazards.
Over 950 billion masks—amounting to 3.8 million tons—have been discarded since the onset of COVID. Once disposed of, masks end up in landfills, where they will take generations to degrade, or are incinerated, where they produce toxic gases.
To counter the huge-scale pollution caused by these disposable masks, researchers have devised a new method to extend the life of discarded masks by breaking them down and recycling them. The recovered polypropylene nanomaterials can be used in electronic devices such as smartphones and LEDs.
Professor Pingan Song, senior researcher and co-author of the study, said the idea has the potential to drastically minimize the environmental effects of disposable masks.
Incinerating waste masks release toxic gases such as dioxins and furans, causing air pollution, while landfilled masks not only take hundreds of years to degrade fully but often generate large amounts of microplastics that cause long-term pollution of water sources, soil and food chains. Single-use face masks – most of which are not recyclable – remain widely used, especially in laboratories, hospitals and other healthcare settings.
Without more public awareness and a sustainable management solution to manage the high volume of waste masks that are still generated every day, they will continue to exacerbate the ongoing pollution crisis.”
Pingan Song, Study Senior Researcher, Co-Author and Professor, University of Southern Queensland
The high-performance thermally conductive nanocomposites (PP@G, where G refers to graphene) were formed in a series of processing steps, including alkaline treatments, extraction, and hot-pressing. The researchers then assessed their thermal conductivity and electromagnetic interference (EMI) shielding capabilities, which showed the nanocomposites possessed an excellent electromagnetic interference shielding effectiveness (EMI SE), meaning they can effectively shield against EMI signals.
The nanocomposites also demonstrated a high TC of 87 W m⁻1 K⁻1, and strong heat dissipation capabilities on LED lights and flexible circuits - outperforming PI films and steel heat sinks used commercially.
Professor Pingan Song added:
"This research presents a novel upcycling method that tackles pollution from discarded masks while converting them into low-cost yet high-value nanocomposite products. It offers industries an affordable, high-performance solution for developing advanced heat dissipation and electromagnetic shielding materials and opens new economic opportunities in electronics and recycling."
Pingan Song, Study Senior Researcher, Co-Author and Professor, University of Southern Queensland
Looking ahead, the researchers aim to partner with industry to scale up the process and develop value-added products, such as heat sinks for electronic devices. They also plan to transform waste masks into carbon nanomaterials within three years.
The study offers a fresh route for tackling the mounting plastic waste crisis caused by discarded face masks. Song called on governments to support these efforts by implementing recycling programs that reduce landfill waste and mitigate environmental harm.
Journal Reference:
Zhang, X. et al. (2025) Highly Thermal Conductive and Electromagnetic Shielding Polymer Nanocomposites from Waste Masks. Nano-Micro Letters. doi.org/10.1007/s40820-025-01796-z