More than 60,000 tons of plastic makes the journey down the Amazon River to the Atlantic Ocean every year. And that doesn’t include what finds its way to the river’s banks, or the microplastics ingested by the region’s abundant and diverse wildlife.

It’s easy to demonize plastic, but it has been crucial in developing the society we live in today. Creating materials that have the benefits of plastics while reducing the harms of traditional production methods is a goal of chemical engineering and materials science labs the world over, including that of Bradley Olsen, the Alexander and I. Michael Kasser (1960) Professor of Chemical Engineering at MIT.

Olsen, a Fulbright Amazonia scholar and the faculty lead of MIT-Brazil, works with communities to develop alternative plastics solutions that can be derived from resources within their own environments.

“The word that we use for this is co-design,” says Olsen. “The idea is, instead of engineers just designing something independently, they engage and jointly design the solution with the stakeholders.”

In this case, the stakeholders were small businesses around Manaus in the Brazilian state of Amazonas curious about the feasibility of bioplastics and other alternative packaging.

“Plastics are inherent to modern life and actually perform key functions and have a really beautiful chemistry that we want to be able to continue to leverage, but we want to do it in a way that is more earth-compatible,” says Desirée Plata, MIT associate professor of civil and environmental engineering.

That’s why Plata joined Olsen in creating the course 1.096/10.496 (Design of Sustainable Polymer Systems) in 2021. Now, as a Global Classroom offering under the umbrella of MISTI since 2023, the class brings MIT students to Manaus during the three weeks of Independent Activities Period (IAP).

“In my work running the Global Teaching Labs in Brazil since 2016, MIT students collaborate closely with Brazilian undergraduates,” says Rosabelli Coelho-Keyssar, managing director of MIT-Brazil and MIT-Amazonia, who also runs MIT’s Global Teaching Labs program in Brazil. “This peer-learning model was incorporated into the Global Classroom in Manaus, ensuring that MIT and Brazilian students worked together throughout the course.”

The class leadership worked with climate scientist and MIT alumnus Carlos Nobre PhD ’83, who facilitated introductions to faculty at the Universidade Estadual de Amazonas (UAE), the state university of Amazonas. The group then scouted businesses in the Amazonas region who would be interested in partnering with the students.

“In the first year, it was Comunidade Julião, a community of people living on the edge of the Tarumã Mirim River west of Manaus,” says Olsen. “This year, we worked with Comunidade Para Maravilha, a community living in the dry land forest east of Manaus.”

A tailored solution

Plastic, by definition, is made up of many small carbon-based molecules, called monomers, linked by strong bonds into larger molecules called polymers. Linking different monomers and polymers in different ways creates different plastics — from trash bags to a swimming pool float to the dashboard of a car. Plastics are traditionally made from petroleum byproducts that are easy to link together, stable, and plentiful.

But there are ways to reduce the use of petroleum-based plastics. Packaging can be made from materials found within the local ecosystem, as was the focus of the 2024 class. Or carbon-based monomers can be extracted from high-starch plant matter through a number of techniques, the goal of the 2025 cohort. But plants that grow well in one location might not in another. And bioplastic production facilities can be tricky to install if the necessary resources aren’t immediately available.

“We can design a whole bunch of new sustainable chemical processes, use brand new top-of-the-line catalysts, but if you can’t actually implement them sustainably inside an environment, it falls short on a lot of the overall goals,” says Brian Carrick, a PhD candidate in the Olsen lab and a teaching assistant for the 2025 course offering.

So, identifying local candidates and tailoring the process is key. The 2025 MIT cohort collaborated with students from throughout the Amazonas state to explore the local flora, study its starch content in the lab, and develop a new plastic-making process — all within the three weeks of IAP.

“It’s easy when you have projects like this to get really locked into the MIT vacuum of just doing what sounds really cool, which isn’t always effective or constructive for people actually living in that environment,” says Claire Underwood, a junior chemical-biological engineering major who took the class. “That’s what really drew me into the project, being able to work with people in Brazil.”

The 31 students visited a protected area of the Amazon rainforest on Day One. They also had chances throughout IAP to visit the Amazon River, where the potential impact of their work became clear as they saw plastic waste collecting on its banks.

“That was a really cool aspect to the class, for sure, being able to actually see what we were working towards protecting and what the goal was,” says Underwood.

They interviewed stakeholders, such as farmers who could provide the feedstock and plastics manufacturers who could incorporate new techniques. Then, they got into the classroom, where massive intellectual ground was covered in a crash course on the sustainable design process, the nitty gritty of plastic production, and the Brazilian cultural context on how building such an industry would affect the community. For the final project, they separated into teams to craft preliminary designs of process and plant using a simplified model of these systems.

Connecting across boundaries

Working in another country brought to the fore how interlinked policy, culture, and technical solutions are.

“I know nothing about economics, and especially not Brazilian economics and politics,” says Underwood. But one of the Brazilian students in her group was a management and finance major. “He was super helpful when we were trying to source things and account for inflation and things like that — knowing what was feasible, and not just academically feasible.”

Before they parted at the end of IAP, each team presented their proposals to a panel of company representatives and Brazilian MIT alumni who chose first-, second-, and third-place winners. While more research is needed before comfortably implementing the ideas, the experience seemed to generate legitimate interest in creating a local bioplastics production facility.

Understanding sustainable design concepts and how to do interdisciplinary work is an important skill to learn. Even if these students don’t wind up working on bioplastics in the heart of the Amazon, being able to work with people of different perspectives — be it a different discipline or a different culture — is valuable in virtually every field.

“The exchange of knowledge across different fields and cultures is essential for developing innovative and sustainable solutions to global challenges such as climate change, waste management, and the development of eco-friendly materials,” says Taisa Sampaio, a PhD candidate in materials chemistry at UEA and a co-instructor for the course. “Programs like this are crucial in preparing professionals who are more aware and better equipped to tackle future challenges.”

Right now, Olsen and Plata are focused on harnessing the deep well of connections and resources they have around Manaus, but they hope to develop that kind of network elsewhere to expand this sustainable design exploration to other regions of the world.

“A lot of sustainability solutions are hyperlocal,” says Plata. “Understanding that not all locales are exactly the same is really powerful and important when we’re thinking about sustainability challenges. And it’s probably where we’ve gone wrong with the one-size-fits-all or silver-bullet solution — seeking that we’ve been doing for the past many decades.”

Collaborations for the 2026 trip are still in development but, as Olsen says, “we hope this is an experience we can continue to offer long into the future, based on how positive it has been for our students and our Brazilian partners.”