Poly (butylene adipate‐co‐terephthalate) (PBAT) and functional blends: Applications, performance tuning, and emerging directions

Poly (butylene adipate‐co‐terephthalate) (PBAT) is a flexible, industrially compostable polyester compatible with conventional processing, yet its broader deployment remains constrained by cost, limited barrier/mechanical performance, and uncertain degradation outside industrial composting. While most reviews emphasize synthesis, properties, and conventional blends, significantly less attention has focused on functional PBAT systems (antimicrobial, sensing, self-healing), biomedical uses, natural-fiber reinforcement, additive manufacturing, and real-world environmental persistence. Adopting a structure-processing-property (SPP) perspective, this review synthesizes PBAT fundamentals, scalable processing routes, commercial uptake, and state-of-the-art blends and composites for packaging, agricultural films, and biomedical applications. Evidence-based pathways toward enhanced functionality and scalability are identified, including compatibilizer-assisted multifunctional blends, AI-guided blown-film optimization, and emerging chemical and enzymatic recycling strategies. To strengthen environmental credibility, a unified validation framework distinguishing certified industrial compostability from marine and ambient biodegradation (ASTM D6691 /D7991; ISO standards) is discussed. Finally, prioritized, testable milestones (e.g., ≥80 % elongation retention with ≥ 3-log antibacterial efficacy) are proposed to guide translation from laboratory innovation to industrial deployment. This review links multi-scale structure, processing control, and application-specific performance targets to support the development of functional, scalable, and environmentally credible PBAT technologies.