Plastics in Practice

Plastics have become indispensable in many sectors: packaging, transport, medicine, the home, construction and much more. In this section, you will find numerous articles on the use of plastics in various contexts.

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Results (111)

  • Rendering packaging sustainability transparent with blockchain technology

    Blockchain technology can revolutionise recyclate traceability. Copyright: biasciolialessandro 30.12.2024 How much recycled plastic is really in a given product? Maximum transparency is a fundamental factor to achieve quotas and sustainability targets, whether it's in terms of consumers, authorities or the manufacturers themselves. Manufacturers who want to disclose how much plastic recyclate is actually used in packaging can only do so if they include the entire value chain. This is a complex challenge. Blockchain technology offers an innovative solution as it allows for seamless tracing along the entire value chain. Challenges along the value chain The complex international value chains represent a significant obstacle to using recycled materials. On the journey from waste to new packaging, there is always the risk of materials being contaminated or replaced by lower-quality plastics. This makes it more difficult to verify whether companies are actually complying with their disclosures regarding the proportions of recycled material. Blockchain technology may open a path to more transparency and traceability. Even more, it could be a game changer. It provides a decentralised database that documents all transactions along the value chain. Each movement of materials and each manufacturing process can be digitally recorded to reassure companies and consumers that the final packaging only contains certified recyclates. How blockchain secures recyclate traceability There are various possibilities for blockchain technology to be used in the packaging industry in order to ensure the traceability and ultimately the certification of recyclates. It offers seamless transparency in the packaging industry. The digital recording of each single movement and change of materials creates an unalterable record. This is accompanied by digital certificates that can be issued for each batch of recyclates. These certificates contain information on the origin and quality of the material. In the blockchain, the certificates can be checked for all supply chain actors. Another characteristic of this technology is the linking of physical materials and digital data through technologies like RFIS tags, QR codes or other identifiers. This allows each packaging unit to be clearly identified and traced along the value chain. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Best practices for traceability: Plastic Bank and Veolia Companies like Plastic Bank and Veolia, who are using blockchain technology successfully to ensure the traceability of plastics and recyclates, show us how it's done. The Canadian social enterprise Plastic Bank uses blockchain to collect and recycle plastic waste in developing countries. The collected waste is recorded in a decentralised database and the waste collectors are awarded digital tokens for their work. To ensure that the origin of the recycled materials can be traced seamlessly and transparently, every transaction is recorded in the blockchain. This guarantees that the certified recyclates are the plastics that were actually collected and that they have not been replaced by new plastics. The French recycling company Veolia also relies on this technology. The company uses blockchain to monitor the origin and purity of post-consumer plastics along the entire recycling chain. To trace every batch from collection to processing into granules, Veolia combines blockchain and RFID tags. A pilot project in Germany has shown how systems based on blockchain can increase transparency and better control recycling rates. Blockchain for the certification of sustainable packaging If packaging must meet specific quotas and comply with statutory provisions, this process can be made transparent and also certified via blockchain. For instance, the proportions of recycled material can be proven. Reusable systems are another area of application. Here, blockchain technology can document the number of reuses and the condition of the packaging to ensure efficient traceability. Blockchain can also support the entire life cycle of packaging by making disposal and recycling traceable in end-of-life management. Legal requirements and greenwashing prevention In light of new statutory requirements for the traceability and certification of recyclates, for example issued by the European Commission or the US Food and Drug Administration (FDA), the blockchain can support companies in fulfilling their documentation duties. This enables compliance with these regulations to be monitored in real time and manipulation to be prevented. And in return, regulatory authorities might find it easier to check companies' disclosures regarding recycling quotas and proportions of material. This would make promises of sustainability more credible and prevent greenwashing. Blockchain as a driver of circular economy Blockchain technology has the potential to fundamentally transform the packaging industry. It offers transparent traceability of materials and builds trust in the authenticity and quality of recyclates. Projects like those of Plastic Bank and Veolia show that the use of blockchain in recycling is already possible today. With increasing technological maturity, the blockchain could become an indispensable building block of a transparent circular economy and ensure the traceability of recyclates in the long term. Source interpack SPOTLIGHT More around Packaging

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  • Formula Student puts plastics in the fast lane

    Plastic as the key to innovative racing cars Exclusively for K-MAG Plastics are an essential component of the racing cars used in Formula Student. Copyright: Formula Student Germany / andrae 07.08.2024 If you loved soapbox derby as a child, you could find yourself at 'Formula Student'. Once a year, students from all over the world meet at Germany’s world-famous Hockenheim Ring (Germany) to compete against each other in single-seater race cars made of plastic. Perhaps the biggest difference to the soapbox race, apart from the more professional construction of the cars, is that the winner is not necessarily the fastest. A number of other criteria are taken into account such as "skills and spirit". In other words, in addition to the performance of the cars in various disciplines such as cornering, acceleration and energy consumption, the jury also evaluates the design of the cars, the teams' cost planning and sales presentation. Plastics as the backbone of Formula Student The plastics industry and its applications are fundamental for the engineers to achieve victory. For their purposes, plastic has a clear advantage: it is lighter than metals, does not rust and requires no lubrication or maintenance. Igus is aware of these advantages and supports the students with its "young engineers support (yes)" initiative by providing free samples, sponsorship and advice. The company is already well-versed when it comes to automotive vehicle parts. Anja Görtz-Olscher, Public Relations Manager at Igus, gives an insight: "Every second bearing that we manufacture ends up in a car. The Formula Student race cars also benefit from this experience." Not only the material properties, but also the diverse production techniques for plastic have advantages for the students. As the racing cars and their interiors are custom-made, with many parts containing complex geometries the engineers benefit from various cutting-edge technologies. SLS (selective laser sintering), 3D printing and rapid prototyping make it possible to manufacture the parts individually and cost-effectively. At Formula Student, the teams compete in various disciplines. The tests and measurements include cornering behavior... ...water resistance and... ...and acceleration and braking performance. In addition, there are further technical inspections... ...and evaluation of the design. Plastics not only play a technical role here, but also an aesthetic one. The winning team can celebrate themselves. Cooperation has advantages for students and plastics companies In addition to Igus, many other companies such as BASF and Sintratec support the students in their preparation for and participation in Formula Student. For example, BASF makes its laboratories available for crash tests and provides advice with its portfolio of engineering plastics and polyurethanes. This results in exterior applications made of high-performance plastics or interior components such as the steering wheel. However, close contact with the plastics industry is not only beneficial for students withing Formula Student. Companies also gain valuable networking opportunities, as the automotive industry is often an important customer sector with which they can deepen their contacts. Another positive aspect for the companies: They can position themselves to students as an attractive and interesting employer. Igus combines the advantages for the students with those for the company: "From a professional point of view, the students have the opportunity to get to know Igus as part of their final theses, practical semesters or internships. Former Formula Student members are already working for us today. Of course, the students of today are also the potential customers of tomorrow, for example when they work in design or development. They can take their experience and knowledge of lubrication-free plastic components with them and apply it directly," says Anja Görtz-Olscher. Companies like Igus support the students with their know-how as well as with components. In her eyes, there is a further advantage: "This collaboration offers us a great opportunity to bring the topic of plastic bearings to universities, as bearings made of steel and metal are still very present in mechanical engineering teaching. After their initial positive experiences with our plain bearing technology, the students also tried out our linear guides and our filaments for the 3D printing of wear parts." Today, Formula Student is much more than just a soapbox derby. In 2024, around 3,000 students from 20 nations will take part and compete in the various disciplines - this year purely electrically! Vehicles with combustion engines last competed in 2023. Cooperation between students and plastics companies is an integral and important part of Formula Student. Both sides benefit from the cooperation and advance the mobility of the future. Without plastics, both the pioneering racing cars on the track and current vehicle models on the road would look very different and weigh a ton more! In 2024, Formula Student will take place from August 12 to 18. Currently 83 teams are registered. You can find more information about Formula Student, the schedule and the participating teams here: Formula Student Germany Kyra Molinari (Editorial team K-Mag) More around Mobility

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  • K meets MEDICA – TPU Films in Medical Wearables

    K exhibitor Covestro presents printed electronic solutions made of polymers at the medical technology trade fair Exclusively for K-Mag TPU films from Covestro offer flexibility and functionality. Copyright: DSTNCTVE 20.12.2024 MEDICA 2024, the leading trade fair for medical technology, is an important meeting place for innovations and new technologies. Covestro, a global player in the polymer industry and a key exhibitor at K, is taking this opportunity to showcase its latest solutions made from thermoplastic polyurethane (TPU) films. These are increasingly being used in the manufacture of medical wearables. Flexible sensor circuits are printed onto the TPU film using silver conductive ink. Copyright: Covestro The flexible and versatile materials offer new possibilities for integrating electronic functions into wearable devices thanks to their printability and excellent mechanical properties. Covestro's TPU films are characterised by their high stretchability and excellent mechanical strength, making them ideal candidates for use in medical devices that require both comfort and durability. Of particular interest is the use of TPU as a basis for printed electronics, where the films serve as a carrier for conductive layers that are applied to flexible substrates. Video: TPU films for wearable electronics In the video, Karin Benbelaid, Global Head for the Medical Segment, explains that these TPU films not only provide the basis for the integration of electronic components, but also enable a cost-effective and efficient manufacturing method. The technology of printing electronic components directly onto films improves production processes and makes the development of new, flexible wearables even more accessible. At MEDICA in November 2024, Covestro presented a series of prototypes using TPU-based materials in medical wearables. These new solutions offer more functionality, improve wearing comfort and open up prospects for wearable devices that are tailored to the needs of patients. Text: Elena Blume (Editorial team K-Mag), Video: DSTNCTVE More around Materials Design

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  • From the children's room to a Circular Economy: Sustainable materials for the toys of the future

    Interview with Philipp Hummel, Head of Sustainability, Schleich Exklusiv für K-MAG Copyright: Schleich 18.10.2023 As a child, many of us could best bring our fantasy world to life with toy figures. Although the beloved miniatures have already often lasted for decades and been passed down from generation to generation, Schleich is now consciously saying "There's more!" and opting for a green transformation. A central challenge: to reconcile longevity and eco-friendliness without compromising on quality. Philipp Hummel. Copyright: Schleich In this interview with K-MAG, Philipp Hummel, Head of Sustainability at Schleich, explains how the industry giant plans to follow its ambitious path toward a circular economy, the exciting process of material selection, and how self-reflection and a spirit of innovation are leading the company toward a more sustainable future. Mr. Hummel, Schleich figures are appreciated for their durability. How will the new material selection affect this? Philipp Hummel: Sustainable play has always been firmly anchored in Schleich's DNA. For over 85 years, we have been producing high-quality and therefore very durable toys. This durability naturally reduces the ecological impact of toys. For example, we know from surveys that 91 percent of respondents have never thrown away one of our figures. To further conserve our planet's precious resources, we are working on sustainable materials for our toy figures and, as a first step, we are ensuring that all our figures will be recyclable and Cradle to Cradle® certified by the end of 2027. Even when developing new materials for our schleich® figures, quality, safety, and durability are top priorities – today and in the future. Only the materials that meet all of our high-quality requirements are approved for our toys, so that children will continue to enjoy their schleich® figures for a long time to come, and so that future generations will be able to enjoy them as well. How is the search for the perfect materials for your ambitious sustainability project shaping up? Hummel: Our multidisciplinary team from the fields of chemistry, sustainability and engineering is working at full speed to develop new, sustainable and at the same time durable materials for our toys. At the same time, we rely on the know-how of our partners and suppliers, with whom we work together on the development of new materials. Various teams at Schleich are involved in the search for the perfect material to meet sustainability goals. Copyright: Schleich In order to find the ideal material for our play figures that meets our high quality and safety standards as well as being recyclable and more sustainable, we test a wide range of different materials both in our own testing laboratories and at our partners' facilities. In addition to mechanical testing, where we primarily test the quality properties of the material, chemical testing is performed to ensure that the material is safe for people and the environment. Only when all tests have been passed successfully, the materials are approved for our toys. Which of your products are already recyclable or biodegradable? Hummel: Most of our figurines are already designed in such a way that they can be easily recycled. Unfortunately, there is currently hardly any possibility to recycle children's toys. When a toy is thrown away, it is usually sent for energy recovery or, in some countries, ends up in landfills. To change this, we have developed our own recycling program: We accept old schleich® figures and ensure that the valuable resources from which they are made are put back into circulation. However, not all of our schleich® figures are very recyclable yet, such as figures that we use glitter or glue for. That's why we continue to develop our figures and materials to make them even more sustainable and recyclable. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates How are you going about redesigning the entire product range in terms of sustainability criteria by 2027? Hummel: We have been working for several years with a large team to develop new, more sustainable materials for our figures. We can show great progress in the area of paints: Since 2022, we have started to paint our products with water-based paint. We are also working with our partners to develop materials and paints that are Cradle to Cradle® certified and are confident of launching our first products soon. We are gradually converting our product range to more sustainable materials. In addition, we are reviewing all our activities and trying to become even more sustainable in everything we do. Not only the plastic material, but also the paints for the figures play a major role in sustainability. Copyright: Schleich What other challenges do you face with these processes? Hummel: A major challenge in developing more sustainable materials for our toys is to meet our own very high quality standards while also meeting the demanding sustainability criteria of the Cradle to Cradle® standard. We have been searching for more sustainable materials that will allow us to continue to make our figures as detailed and authentic as possible for several years now, and we are pleased to be making great progress in this area. Will the toy also change from the children's perspective? Will it look or feel different? Hummel: The quality and safety of our products are Schleich's top priority. The quality, feel and look of our products are not affected by the use of more sustainable materials. Attention to detail, authenticity and high quality are and will remain our product values that define us. A schleich® lion will always be a schleich® lion and will continue to feel the way children all over the world love it. We make no compromises here. We are working at full speed to find sustainable and recyclable materials that meet these demands. The authentic Schleich feeling remains the same for the children – the most important critics. Copyright: Schleich What are the expectations for toys in 2030 – as opposed to 50 years ago? Hummel: In light of the limited resources of our earth, the importance of quality and durability of toys, but also their recyclability, is becoming increasingly important. Our figures are timeless and are often passed down from generation to generation. Thus, children today often play with the schleich® figures of their parents or even grandparents. In addition, we have set ourselves the goal of making all our figures recyclable by 2027 and having them certified according to the sustainability principles of Cradle to Cradle® in order to make a significant contribution to the recyclability of toys. Nastassja Lotz (Editorial team K-MAG) More around Plastics in Daily Life

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  • They see me rollin' - Plastics in bicycles and current best practices

    Exclusively for K-MAG Cycling has a positive impact on climate protection. Copyright: kikea3 Cycling has a positive impact on climate protection. Copyright: kikea3 04.10.2023 Anyone who chooses the bicycle as a means of transport instead of the car every day saves the environment 3.2 kilograms of climate-damaging CO2. Researchers have determined this with a sample analysis based on data from the PASTA project (Physical Activity through Sustainable Transportation Approaches). In addition, plastics can help reduce CO2 emissions from the production and transport of bicycles. They can be used in all components and therefore make cycling even more environmentally friendly. This is shown by the following examples: Off to new adventures: Lion Bike from KraussMaffei The Lion Bikes, developed by former professional racing cyclists Marcel Kittel and Tony Martin, ensure more safety for our kids in road traffic. The bike is manufactured by Weber Fibertech on an MX 1600 from KraussMaffei and has a clean look with a special paint that makes the frame glow. The frame and front wheel fork of the sustainably produced bikes are made of a new, resource-saving material mixture of high-performance polymers and recycled carbon fibres. Comparing the production of Lion bikes with conventional frames and front wheel forks made of aluminium, the CO2 emissions for each bike produced are 67 % lower. In addition, thanks to the "Made in Germany" seal of quality, supply chains and transport routes are shortened, which is also an important aspect of sustainability. Protect the environment with the Green Marathon from Schwalbe Schwalbe and Pyrum present the world's first bicycle tyre that is made from used bicycle tyres, among other things, and closes the material cycle. According to the manufacturer, the "Green Marathon" is also made from 100% fairly traded natural rubber. In addition, 100% recycled industrial carbon black (rCB) from Pyrum is used, which serves as a direct product of the recycling process and replaces fossil industrial carbon black. The production of the bicycle tyre saves more than a third of CO2eQ compared to the previous model. Pro One Aero from Schwalbe: A unique riding performance Schwalbe's next-generation aerodynamic competition tyre was developed in cooperation with Scott, Syncros and the Swiss engineering firm Radiate Engineering & Design. Schwalbe's developers have optimised the tyre shape for modern wide rims in the wind tunnel. Different constructions are used for the front and rear wheel. The focus for the front tyre was on aerodynamics and reduced weight. During the development phase, numerous professional teams and triathletes were involved and have already put the tyre to the test during competitions. The first large-scale use of the Pro One Aero is planned for the Ironman World Championship in Nice and Kona. From "ocean plastics" to "motion plastics": The Urban Bike from Igus The Urban Bike from igus is the world's first completely recyclable all-plastic bicycle and is more durable and robust than other bicycles. "The plastics in the landfills of this world are becoming a valuable resource," says Frank Blase, Managing Director of igus. Another advantage: Since all components are made of plastic, the bike does not rust and you don't have to worry about maintenance. Thanks to the futuristic design of the bicycle, igus has already won the prestigious German Design Award 2023. Schwalbe's extensive recycling system In a cooperation between Schwalbe and Pyrum, a recycling system for used bicycle tyres was developed: The "Schwalbe Recycling System" enables the holistic recycling of used tyres of all brands. A special Schwalbe recycling box for used bicycle tyres is available at participating specialist retailers. With its pyrolysis system, Pyrum takes care of the mechanical processing and pyrolytic recycling of used tyres. As a result, used tyres are turned into new ones. According to Pyrum, the process saves a total of 80 % CO2. More efficient raw materials: A cooperation between Isoco, V Frames and the Lehvoss Group Isoco and V Frames will collaborate with Lehvoss Group on high-performance fibre-reinforced composites, including long carbon fibre and biopolymer carbon compounds. The main focus of further development will be on increasing the performance of the raw materials. With this step, future frames can be lighter and more impact resistant. V Frames produces sustainable bicycle frames and reduces the carbon footprint by 64% compared to traditional aluminium frame production according to an LCA by the University of Linz, Austria. In addition, V Frames and Lehvoss focus on compounds containing recycled fibres from different industries for each new frame.100% of the products are recycled into new bicycle component products at the end of their service life. The entire production takes place in Germany. Stylish and sustainable: The bicycle bag from BASF and Baesiq The new 2-in-1 bag "Pendik" from Baesiq and BASF can be used both as a shoulder bag and as a bicycle bag. The functional bag is made from sustainable polyamide that is derived from pyrolysis oil from used tyres. "With our partner Baesiq, we are actively advancing the topic of circular economy and are also looking forward to launching more bag collections this autumn," says Frank Reil, Head of Marketing and New Business Development & Sustainability Polyamides at BASF. CoreTechnology: 3D printed bicycle For the first time, the team of the software manufacturer CoreTechnologie has created a particularly light and affordable bicycle made of 3D printed aluminium components. The fully operational singlespeed version of the bike weighs only 7.1 kilograms ready to ride, yet it is highly robust and resilient and can be easily moved on differently shaped paths. An easy ride with the Maniac & Sane cargo bike Cargo bikes are becoming more and more popular and are dominating European city centres. However, an electric cargo bike weighs up to 60 kilograms, which often makes it difficult to steer it through the streets. Now, the start-up Maniac & Sane has almost halved the weight of the vehicle compared to what is available on the market with a cargo bike made of fibre composite materials and 3D-printed components. Thanks to SLS technology, it was possible to develop functional components and integrate them into the lightweight concept of the cargo bikes without having to make any compromises in terms of design or function. After all, with a bicycle you can not only explore the world, but also improve it. Sarah Dietsche (Editorial team K-MAG) More around Mobility

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  • Plastic Recycling: Plastic Waste Becomes Furniture

    Industrial designer combines plastic recycling with design and produces furniture from waste in Africa Exclusively for K-Mag Copyright: Johannes Kastner 25.10.2023 Updated on 29/10/2024: We have revised this article to include the latest developments and provide the most up-to-date information. Millions of tonnes of waste end up in our environment every year. This problem is particularly tangible in the global south. But innovative approaches and creative solutions can make a difference. Johannes Kastner focuses on one such solution: combining plastic recycling and design to not only combat the waste problem but also create social added value. In an interview with K-Mag, Johannes Kastner talks about his inspiring trip to Senegal, his newly developed manufacturing method for injection moulds and how local cooperation can contribute to global change. Plastic waste as a design material: furniture production with a focus on recycling Johannes Kastner, industrial designer and graduate of the Kunsthochschule Kassel. Copyright: Johannes Kastner Mr Kastner, in your diploma thesis you deal with "open plastic recycling in the global south". Why did you choose this topic? Johannes Kastner: I got access to this topic through a collaboration with the Austrian company Plastic Preneur and the Kunsthochschule Kassel. My project partner Raphael Nyabale from the Kankuma Refugee Camp in Kenya told me about the problems with plastic waste in the global south. During my later trips to Senegal, I saw this with my own eyes, so that my diploma thesis took up this topic. The project made me realize how important the recycling of plastic waste is for solving the waste problem in the Global South. During your study trip to Senegal, you worked with local craftsmen and women as part of the "DesignUp" project. Can you tell us more about that? Kastner: The "DesignUp" project provided a perfect platform for cooperation at eye level. Together with the craftspeople, I designed three stool models from different plastic waste and old construction steel. I think the diversity of the results from different design directions makes the project particularly meaningful. The project shows how design and plastic can be harmonized to create sustainable products. One of the stools is covered with a mesh made of PE drinking bags, which are lying around in huge masses in Senegal. The so-called sachets provide the cheapest source of drinking water in Senegal and something like that has to change. Injection molding and craftsmanship: combining innovative technologies for sustainable design Plastic connectors are used for furniture construction. Copyright: Johannes Kastner How did you go about developing the furniture pieces? Kastner: We use plastic connectors for the construction of the furniture, which combine different materials. In my studies I developed a new manufacturing method for injection moulding tools that enables us to produce injection moulded parts like the connectors in cost-effective small series. The other elements of the furniture are produced by craftsmen and women who bring the knowledge of their trade into the design process. The combination of handicraft production, injection moulding and great flexibility is a door opener for the African market. In a recycling workshop, Johannes Kastner restores furniture in collaboration with local people. Copyright: Johannes Kastner You graduated from the Kunsthochschule Kassel with a major in industrial design. How did that influence your approach to this particular recycling project? Kastner: Thanks to the Kunsthochschule Kassel, I was able to freely develop my manufacturing method and thus find the right path piece by piece. We have a diploma course in product design that allows you to study very freely. Apart from that, there has been a cooperation between the Kunsthochschule Kassel and the company Plastic Preneur for a few years now, without which I probably wouldn't have found access to this topic at all. Local recycling workshops as a model for the future: plastic as a resource for Africa What challenges do you see specifically in Africa or the Global South, and how do you address them? Kastner: I see it as the greatest challenge to create a successful transfer that combines new technologies, culture and humanity. Unfortunately, this is a difficult undertaking because the strong imprint of Western nations usually has a bitter aftertaste. The most important thing for me in my work is that the cooperation happens at eye level and that cultural realities are respected. The next step is to find the right people you can trust and to get support from companies and politicians. In my opinion, the foundation for sustainable development is only laid when something is initiated at the political level. Millions of tons of waste end up in our environment every year, which is especially challenging in Africa. Copyright: Johannes Kastner You will soon be travelling back to Senegal to realise your idea of a start-up. What is your plan look like? And what is your vision behind it? Kastner: I would like to set up a recycling workshop in the Senegalese capital Dakar recycling workshop together with motivated people from my network. The idea is for this recycling workshop to become a self-sustaining and become a model project for the establishment of my start-up, which I will which I will be founding in Kassel next year. My start-up will be a social enterprise with a focus on setting up and running such local recycling workshops in the global South. We want to work with companies and research with companies and research institutions to accelerate our developments. My vision is in line with the Precious Plastic Movement , which sees plastic as a valuable resource. Everyone has a right to an environment free of plastic waste. And to achieve this goal, especially in the Global South, simple and cost-effective means must be used to recycle the flood of plastic waste. Contact: Designer Johannes Kastner | Tel.: +49 157-85 05 11 11 | Mail: jojo.1396@web.de News: Johannes Kastner Wins Second Prize at the James Dyson Award 2024 With SOCIAL PLAST, Johannes Kastner has developed a method of using high-performance concrete (UHPC) to produce cost-effective and energy-efficient molds for the injection molding process. This technology is particularly suitable for small batches of 500 or more and is intended to make injection molding more accessible in developing regions. The jury recognized both the innovative potential and the social added value of the invention. Elena Blume (Editorial team K-Mag) More around Materials Design

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  • Thermoplastics in aircraft construction – less weight, more future

    Interview with Dr.-Ing. Frederic Fischer, former Project Manager "Large Passenger Aircraft", Center for Lightweight Production Technology (ZLP), German Aerospace Center (DLR) Exclusively for K-MAG MFFD component before transport. Copyright: DLR 20.09.2023 Every gram counts: In aviation, a weight reduction of just one kilogram can save up to 25,000 litres of fuel annually. Plastics can be the key to this. The German Aerospace Center, for example, uses carbon fibre-reinforced thermoplastics to make aircraft fuselages more resource-efficient. Within the framework of the Large Passenger Aircraft project, fundamentally new technologies have even been developed for this purpose. In an interview with K-MAG, Dr.-Ing. Frederic Fischer talks about the current challenges for aviation, the extent to which the use of plastics and the newly developed manufacturing technologies are more climate-friendly and cost-effective. Dr Fischer, what challenges is aviation currently facing? To what extent do you address them in the Large Passenger Aircraft project? Dr.-Ing. Frederic Fischer: Aviation is facing the urgent task of becoming more climate-friendly and sustainable. For decades, we relied on aluminium as the main material. But in today's world, with its increased focus on environmental protection and resource efficiency, this is no longer enough. The Large Passenger Aircraft project aims to reduce fuselage weight by 10 % and running costs by 20 %, which will revolutionise aviation. Innovative plastic component: the multi-functional fuselage demonstrator (MFFD) Dr.-Ing. Frederic Fischer. Copyright: DLR In the project, you developed a fuselage component. What is it made of? What are its special features? Fischer: Our multi-function fuselage demonstrator (MFFD) is made of a special plastic: carbon fibre-reinforced thermoplastic (LM_PAEK). Compared to aluminium, this material is lighter and also has the ability to be reshaped when heat is applied again. This makes repairs and recycling easier. What impact does the use of CFRP have on sustainability compared to aluminium? Fischer: CFRP offers numerous advantages over aluminium. Not only is it lighter and thus more fuel-efficient, but it is also recyclable. This leads to less waste and reduced energy consumption over the life cycle of the aircraft. To the LinkedIn profile of Dr. Fischer In-situ skin taping. Copyright: DLR You have redeveloped some of the technologies and tools used to manufacture the MFFD. To what extent was this necessary and what were they in detail? Fischer: Our main motivation was to make aviation more sustainable. To achieve this, we had to make the transition from aluminium structures to carbon fibre-reinforced thermoplastics in aircraft production. This transition also required the development of new manufacturing technologies. The three core innovations are: Laser-based in-situ fibre deposition: Here we use a robot that precisely heats material strips by means of a laser and deposits them in layers. This technique minimises material waste. Continuous ultrasonic welding: Instead of riveting, we use this method to connect the longitudinal reinforcements, the so-called stringers, to the outer skin. Electrical resistance welding: We use this method to weld the transverse reinforcements, the so-called formers, to the skin. To do this, a welding element in the joining zone made of carbon fibre is exposed to electricity, which heats it up and melts the components. By using these technologies, we can fully exploit the advantages of the new materials and significantly reduce the production effort. Integration of the stringers by continuous ultrasonic welding. Copyright: DLR What were the individual production steps for the MFFD? Fischer: The production took place in several specific steps: Fibre deposition: A ceiling-mounted robot used a laser to heat strips of material and lay them down in layers. This formed a laminate of fibre-reinforced plastics. Reinforcement of the outer skin: The next step was to reinforce the finished outer skin with the continuous stringers. They were attached by means of the newly developed ultrasonic welding. A robot with a precise path correction was used for this to effectively join the stringers. Application of the transverse reinforcements: Following this, the transverse reinforcements, our formers, were added by electric resistance welding. Final connection: Finally, the longitudinal and transverse reinforcements were welded together. Due to the confined working space, we combined a standard robot with a smaller lightweight robot to ensure precise welding of the fasteners. Advantages for sustainable production Integration of the ribs with the resistance welding process - the welding bridge developed in the project is used. Copyright: DLR What advantages do these new manufacturing processes bring over conventional methods in terms of production costs and sustainability? Fischer: Our new manufacturing processes reduce production time by up to 40 %, which brings significant cost savings. Since we have less material waste and can do without the autoclave process, we are also more resource-efficient. Overall, these processes increase both the economic efficiency and sustainability of production. What happens now with the MFFD shell? Fischer: After successful completion, the MFFD shell was delivered to Premium Aerotec, where the final machining took place. It will now be transported to the Fraunhofer Institute in Stade for further processing. Finally, Airbus will validate the technologies in Hamburg. These are exciting developments and we look forward to driving progress in this area. Completed demonstrator; Copyright: DLR Elena Blume (Editorial team K-MAG) More articles on this topic in K-Mag! Find out here how thermoplastic fiber composites are making flying more climate-friendly! You can read about how special surface coatings affect flying here! More around Mobility

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  • Huafeng, Cyclone and Covestro collaborate to provide sports shoes and shorts with reduced carbon footprint

    Copyright: wirestock 02.10.2023 Team Sonnenwagen, a student team from RWTH Aachen and FH Aachen, Germany, is committed to more sustainable mobility using renewable energy. With a self-constructed solar racing car, they once again plan to take part in the Bridgestone World Solar Challenge in October 2023 in Australia. The team also attaches great importance to a more sustainable sports kit. Huafeng, a leader in textile technology, supports this request by providing more sustainably made athletic shoes and shorts for team outfits. For this purpose, Huafeng used a partly bio-based polyurethane (PU) dispersion from Covestro, the main sponsor of Team Sonnenwagen. The new official team equipment provided by Huafeng features shorts and sports shoes with designs using Huafeng's newly launched HAPTIC ® textile coating system, which contains partly bio-based INSQIN ® PU dispersions from Covestro. In addition, fabrics for the garments and shoes are made by Huafeng based on Cyclone recycled polyethylene terephthalate (rPET) yarns derived from post-consumer plastic bottles. The shoe upper material is made of 100 percent Cyclone rPET, while the shorts consist of 86 percent Cyclone rPET and 14 percent Spandex for ensuring a comfortable fit. Lina Schwering, Team Manager of Team Sonnenwagen Aachen: "Our new official equipment looks fantastic – and we're particularly excited about its sustainability benefits! Combined with its excellent performance, it fits well with our vision for a more sustainable mobility future. We’re grateful for the continued support of Cyclone, Huafeng with its HAPTIC ® products, and Covestro as we pursue this vision." The next generation of textile coating The design of the sports shoes for Team Sonnenwagen was produced using Huafeng's proprietary HAPTIC® Art textile coating system with partially bio-based INSQIN® PU dispersions from Covestro. Source: Huafeng Developed by Huafeng using Covestro's partly bio-based PU Impranil ® CQ DLS/1, the HAPTIC ® Art textile coating system used for the shoes enables especially outstanding aesthetics, improved mechanical performance, and reduced production-related emissions. Thanks to its high solids content and thixotropic properties, the system allows manufacturers to achieve a high coating thickness, making it well-suited for creating coatings with detailed images and sophisticated 3D effects on apparel and footwear. Images and textures applied using the HAPTIC ® Art ink system have undergone a series of tests for properties such as flexibility, adhesion, and resistance to hydrolysis, washing, and abrasion. The excellent results demonstrate that the Art ink is particularly suitable for coating on high-performance sports footwear. In recognition of its excellent mechanical properties, Huafeng's ink coating system recently received the ISPO Best Product Award. Dr. Thomas Schmidt, Director of Innovation & Creation at Huafeng: "HAPTIC ® Art ink represents an important expansion of our aesthetic coating capabilities, offering exceptional design versatility along with substantial environmental benefits. For example, the new Team Sonnenwagen shoes deliver savings of 260 g CO 2 e per pair compared to conventionally manufactured sports shoes. We look forward to developing even more sustainable solutions that help drive the future of textile coating." Toward a more sustainable sportswear industry This is how the shorts of Team Sonnenwagen's new sports kit look like. Source: Huafeng With strong environmental credentials, this new coating system can also help meet the growing demand for more sustainable sportswear. Traditionally, sports apparel and footwear have relied heavily on virgin fossil-based PET materials and PU coatings to achieve the required performance, appearance, and durability. However, by combining Huafeng's textile coating expertise with Covestro's partly bio-based INSQIN ® PU technology, Team Sonnenwagen's new equipment proves that a more sustainable approach is possible. Dr. Torsten Pohl, Head of Global Textile Coatings at Covestro: "This new textile coating system represents a major step forward in terms of both performance and aesthetics. Covestro's partly bio-based Impranil ® CQ PU dispersion plays a major role in the shoe's strong environmental credentials, contributing around 80 g to the overall CO 2 e savings. This technology will enable garment and footwear manufacturers to create products that not only look incredible but also deliver a reduced environmental impact." Quelle Covestro AG More around Plastics in Daily Life

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  • Covestro and HiPhi launch joint laboratory on advanced material solutions for future mobility

    Copyright: duallogic Copyright: duallogic 08.12.2023 The automotive industry is making intensive efforts in decarbonization while going smarter, and innovative material solutions can make an important contribution to achieving this goal. In light of such trends, Covestro and Chinese premium electric vehicle brand HiPhi unveiled a joint laboratory at the China International Import Expo (CIIE) to advance low-carbon footprint material solutions and smart technologies for future mobility. The joint lab will mainly focus on the commercialization of low-carbon material solutions in future EV models and the establishment of relevant standards, as well as the development of next-generation smart surface technologies and battery solutions. This initiative builds upon a cooperation agreement signed between the two companies at the CIIE last year. "We're delighted to deepen our collaboration with HiPhi," said Dr. Markus Steilemann, CEO of Covestro, during the unveiling ceremony at Covestro's booth at the CIIE. "We set out to address the key challenges of future mobility with the launch of the joint lab. With our common commitment to pioneering low-carbon smart mobility and by combining our strengths and resources, we believe the lab will accelerate the automotive industry's transformation towards a smarter and climate-neutral future." Dr. Markus Steilemann, CEO of Covestro (right), and Dr. Chen Jun, Co-CTO of HiPhi, use the CIIE to present their new joint laboratory for more sustainable and innovative automotive developments. Source: Covestro "HiPhi aims to redefine the luxury brand in the new era. We are accelerating the adoption of intelligent and low-carbon technology in smart EVs to provide global users with a safe, efficient and sustainable travel experience, thereby changing the future of mobility and contributing to society," said David Ding, Founder and CEO of HiPhi. "Covestro's advanced material expertise is key to helping us achieve this vision. The establishment of our joint laboratory stems from Covestro's recognition of the innovative strength represented by HiPhi and other Chinese companies. We also aspire to empower our global partners and foster mutually beneficial relations through the CIIE." On display at Covestro's booth at the CIIE is the HiPhi Y, the latest luxury SUV that incorporates advanced polycarbonate solutions from Covestro, most notably in the headlamp and LiDAR lenses. As EV becomes increasingly smarter, the headlamp presents new opportunities in digital communication beyond lighting. On the HiPhi Y, the headlamp lenses are turned into a projector to display signs and patterns in front of the vehicle, creating an interactive interface with pedestrians and other vehicles. Covestro's high optical performance Makrolon ® AL solutions offer the needed dimensional stability, UV resistance and high transparency required for this application. In the LiDAR lenses, the Makrolon ® AX portfolio demonstrates superior performance compared to glass, including excellent infrared transmittance, shaping curved surfaces and impact resistance against stone chips. They can also endure the working environment of LiDAR at temperatures from 110 to 115 degrees Celsius for extended periods. The HiPhi Y electric SUV at the Covestro booth at CIIE is also an expression of the good cooperation between the two companies. Source: Covestro "As the mobility industry embarks on a journey towards carbon neutrality, the demand for circular, low-carbon footprint materials is growing rapidly and will only accelerate in the near future," said Lily Wang, President of the Engineering Plastics segment at Covestro. "We hope to collaborate with more like-minded companies, like HiPhi, to accelerate the decarbonization trend and pioneer smart technology development at the same time." HiPhi has been a long-term partner of Covestro since 2018. Covestro's material solutions have been applied to HiPhi's flagship models, such as the polycarbonate solutions that enable a "smart" B-pillar equipped with complex functions in the all-electric SUV HiPhi X. HiPhi Z, a smart sports sedan, employs polycarbonate grades for the touchpad switch on its steering wheel – enabling a futuristic interactive design – as well as high performance waterborne polyurethane adhesives for auto interiors. Covestro AG More around Mobility

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  • "Designers love solving problems."

    Interview with Page Beermann, Design Director, and Sue Neuhauser, Senior Design Manager for CMF, Faraday Future Exclusively for K-MAG Copyright: Faraday Future 14.10.2022 Chris Lefteri: You developed a CMF Design strategy from the ground up, with a new brand and one particularly focused in the digital/physical world and I am really interested in how you see plastics in this brand. But let's start with an easy one – can you describe your backgrounds and your day-to-day jobs? Page Beermann: Sure, I'm the Design Director at Faraday Future. Prior to this role, I was an automotive designer at BMW Designworks and BMW AG for 18 years. At Faraday we are very much about user focus first and deriving all our products' features and characteristics from user needs. The silhouette and proportion of the FF 91, for instance, has a mono-volume proportion, and the windscreen is very far forward on the car in order to maximise the footprint of the vehicle. This means users get the most possible interior functional space for the given vehicle size. We start with the user need and that evolves into the overall form language of the car. Our brand is also focused on digital integration and the user needs that exist around how we live in the digital world. These are the brand pillars that we translate into a design language and bring into the car. That's what I oversee here. Sue Neuhauser: I'm the Senior Design Manager for CMF at Faraday Future, which also includes working on innovation. I have been in the European vehicle OEM world at Audi, Magna and MAN Bus & Truck in Exterior, Interior and CMF Design, before I moved to the start-up world in California in late 2010. Since than I have worked with Tesla, Neuron EV and other vehicle start-ups, including founding my own business before returning to Faraday. My experience - especially over the last 12 years in EV-start-up industry here in the US, helped me tremendously to create better creative and functional processes and being creative while innovative. In CMF Design it is important to identify and understanding future needs, markets, and consumer trends, including requirements and the ability to react to those macro-trends. We can push the boundaries in smarter and faster ways to achieve more efficiency. Copyright: Faraday Future Lefteri: When you were building and defining the CMF Design, what was the brief and how did you approach this idea of the user focus? Was there something in particular – you wanted the users to feel, an emotion you wanted them to feel? Neuhauser: The brief was to create a futuristic design and user experience with a focus on tech – luxury, creating a new class defining species of vehicle. The user should get the feeling of stepping into the future when entering our vehicle. With the FF91 CMF Design we achieved a seamless connection and integration of surface design and technology elements, bringing the exterior and interior of the vehicle design together. A core aspect on our CMF approach was to achieve a design were technology and surface flow together through inside and outside. Lefteri: Are there any examples you can cite of that? Neuhauser: If you look at the information flow regarding the interface structure of the exterior and interior, for example – which are part of the seamless technology flow of the vehicle interior and exterior – they embed themselves into very exclusive and premium appearing high gloss piano black surfaces – the interface & information only appears when required or the screens are in use – it is about bringing surface design and technology together through smart materials and finishes. One example is the seamless information flow on the exterior and interior. We have smart technology layers hidden in premium high gloss piano black surfaces that are part of our exterior and interior design theme. Information and interfaces are coming alive and visible when required or screens are in use. Lefteri: And you mentioned the three key words of tech, luxury and sustainability. How do you bring those three themes together within CMF Design? Neuhauser: First, we need to define where the future is heading and what this would mean specifically for the Faraday Future brand and its product segments. We research and analyse trends and innovations outside of the vehicle world and generate creative directions jointly as cross-functional design team. We (as Design team) - work closely with all internal departments to understand the vehicles product placement, cost, and its required functionalities to identify future technology to integrate into the car and therefor into the Vehicle Design. The customer expectation and experience regarding a "class defining" futurist tech - luxury product plays a core role in our design research and finding phase generating first concepts and moving them further along into production. The sustainability aspect and Material story is of equal importance to us and is also part of the "futuristic tech luxury" approach. We strive to find and implement better solutions that will reduce the companies carbon footprint and will have a global eco-conscious impact. From CMF Design side, we research and analyse new sustainable material solutions and design innovative materials, colors and finishes catered to the FF brand that seamlessly integrate future technologies and elevate the vehicles exterior and interior surface design. Lefteri: Let's talk about luxury and premium. Customers obviously have very established perceived ideas of what luxury means, particularly in a car. How do you define that for something that is very much future-based? How do you re-define what premium is? In your own words, I read somewhere, you’re "redefining the world of mobility". How do you do that while giving the users a perception of premium and luxury and at the same time embracing sustainability? Neuhauser: Luxury has redefined itself over decades and is ever changing. Time and space are in today's fast paced world very precious and play a core direction when we talk about luxury. Offering the occupant, the perfect space and comfort to travel, rest and work in a confined space, such as a vehicle interior, is difficult but can be accomplished through innovative and modular surface design, clever packaging and an a cohesive and smart CMF Design. Setting the right mood, flavour and feeling by creating the perfect sensory and immersive experience for the user is part of how we approached the Design of our Colors, Materials and Finishes that go hand in hand with our Vehicle Surface Design. When you take a seat in the rear of the FF91 you have the possibility to recline into a zero-gravity seat position, with the ability to take all pressure of your body and putting yourself into an almost weightless resting position. We emphasized this experience with a luxurious soft and organic Leather the customer engages with, and its ability to regulate your body temperature due to its properties and the seats functionalities. This super fine Nappa Leather we designed specifically for our FF91 Vehicle is an organic and completely natural material, sustainably sourced and produced from our supplier that has negative carbon footprint. In this case Leather remains a premium and luxurious material, designed, sourced, and produced in an eco-conscious and innovative process that adds to its specific craftsmanship execution and the perceived quality which ultimately is a luxurious experience for our users. Copyright: Faraday Future Lefteri: And just looking at the technological part of this. There's lots of lighting in the car can you tell me about how that fits with the CMF Design? Beermann: There's actually a lot of lighting throughout the vehicle interior and exterior. On the interior it's mostly there to support very precise control over the atmosphere. The user can select which color or mood or function they want that lighting to support, whether they are in spa mode with an intention to relax, or in a work mode with an intention to focus, the lighting scenarios support that. Lefteri: It seems unique how you're using the lighting. You've given the ambient lighting examples. But you use lighting more so than other car interiors. Did that provide any challenges in terms of plastics and integrating technology with the lighting? Beermann: Using plastics really enabled the use of lighting. It allows us different approaches to manufacturing and form factors and allows us to control where the light goes. It’s very strategic the way the lighting and the plastics were used in combination. To your previous point about these pillars, a sense of luxury is hard to define. You can say that a villa that's partially gilded and has marble floors conveys a sense of luxury. In the automotive world, using fine materials like leather with nice quilting and stitching, with wood décor, is traditional luxury. There was a phase for a while where carbon fibre was understood as having some luxury characteristics. If you get a chance to sit in an FF 91 you will see the approach is a little bit different. We have a layering philosophy with our design language. There's a technology layer, there's an experience layer, there's a comfort layer. We've broken that up in terms of where the materials sit. Any contact surfaces, where you're physically contacting the interior, these are really nice materials. Be it leather or PUR, we make sure the hand on those materials is a joy to interact with. You feel on a tactile level bathed in these luxury materials. Then when you interact with the information, and the displays, the tactile experience is very different. We've also made sure through coatings, and the design of those surfaces, that it’s also an exceptional experience. Touching a screen isn’t always pleasant. Running your finger across a piece of glass doesn't give you much information. We’ve done some things we can't talk about too much, to give you an FF specific haptic experience. Whether it's this tactile soft experience or whether you're interacting with the information itself. Lefteri: It's very interesting how you address on such a fine level the idea of haptic, the sensory experience to provide luxury and premium. You mentioned wood. That's traditionally a luxury material. What did you do to replace that sense of luxury without using wood? Did you treat plastic in a certain way? Neuhauser: We played with a variation of "man-made" materials like plastics. The overall benefit of a "man- made" material is that you can design it the exact way you need it to meet your purpose, specifications and performance – which also leads into the design aspect looking at the material appearance and how it feels. Plastics have come a long way and can cater to many aspects or functionalities as well as experience levels by integrating smart tech. They also have great weight, cost, and manufacturing benefits. We figured that working with innovative plastics and designing those in different ways throughout the vehicle, we have the ability to create a new sensory and luxurious experience. Furthermore, we achieved to tie the interior and exterior surfaces and its technology flow closer together as one entity. Chris you mentioned Wood – I am a big fan of wood as it has a very amazing feel and sensory experience, but because it is a natural grown source it deviates a lot and make the material process of creating "identical" interior parts very difficult. This means a lot of part get thrown away not meeting the specifications and quality standards we have to go through in this industry. This also means we are adding to the landfill problem while cutting down trees. Wood is a resource that needs time and space and specific climate to grow depending on the kind of wood. An amazing alternative is Hemp wood as the plant grows extremely fast and also gives off an amazing level of oxygen and requires very little water – which is beneficial for our climate. Those materials are areas we are investigating in of course. There are hybrid solutions between plastic and sustainable wood that are now getting into more feasible directions to use and I am super interested in for the FF brand. Lefter: So here's a tough question. Do you believe that plastics can still provide that sense of luxury even though it has a negative perception? Beermann: I think that the negative perception is somehow from a prior era. If you're in the plastics world now, there are a million options for plastics that feel amazing to touch, and have an amazing quality when light hits them. I would say 90 percent of the time customers don't even realise they're interacting with plastics, because they think it’s metal or they think it's something else. I think that stigma is long gone for us; we don't really think about it. Neuhauser: Yes I do think so Chris, like mentioned in a comment before – plastic have come a long way and a lot of innovation has been created with and around the plastic and its hybrid materials including 3 d printing possibilities and combining natural and man-made components. The ability to create surfaces that have an amazing smooth and silky touch while generating a soft "drag" when touching utilizing silicon coatings for example. Plastics can feel and appear like a honed ceramics but are a fraction of the weight and cost which is pretty amazing. Not to mention the anti-bacterial properties and cleanability which play a tremendous role since the pandemic. Lefteri: Let's move on to this idea of co-creation which you have quite prominently on the Faraday Future website. Co-creation is about the customer of course but does it also involve the way you work within a design studio? Beermann: It does. And co-creation is a philosophy. It's deeply embedded into the brand. In the past, you don't really want to create something and tell the world "this is the most amazing thing!" You need to interact with all of your potential customers and glean their knowledge and their desires. That's the base philosophy for product development at Faraday. During product development cycles – whether it's early in the ideation phase or it's later on in the implementation phase – we actually bring in groups of customers or reservation holders and we do workshops with them. Their ideas will sometimes end up in the product directly. For example, a customer was very interested in having a private environment in the rear of the FF 91. Their suggestion was to create a physical barrier between the front seat row and the rear seat row, like with a taxi cab for example. We worked through that idea with this customer, and the best solution was not physical but using audio software to create sound zones. This is the kind of feedback we get from our reservation holders, because they have very specific use cases, especially with this premium price class, and that really helps us create unique selling points for Faraday Future. Lefteri: Does that co-creation ever involve any hands on and playing with materials? For example, with testing, even on a basic level without getting supplies, do you get samples from a CMF lab and ask users for opinions? Beermann: For sure, that's exactly what we do. We lay out a lot of samples from our library. We do internal colour testing. We create a variety of colour concepts for, let's say, exterior paint, and then we get feedback from our customer base. We have a couple of mechanisms for that: we like to do it 1-on 1, in person, in the studio, as well as we get information through our app. We'll post different colour concepts on our configurator, and get feedback from the users that way as well. Lefteri: I'd like to go back and touch on this idea of what it's like to start a brand and define it from scratch versus both your previous experiences where that’s a very well-established brand. Can you just describe what that’s like – what do you prefer? Beermann: For me, that's the reason why I left BMW after 18 years. There were lots of different learning opportunities at that OEM. But I was never asked to think about defining the brand over. It was always through the lens of creating design proposals and shifting brand perception through the product design. Future Faraday was a blank sheet of paper, there was no logo, there wasn't even a name. You can imagine the amount of churn that happened, in terms of what it was really going to be about, it was so exciting. It’s a designer's dream. Because designers love solving problems. We're puzzlers. You get a kick out of solving that Rubik's cube. When there are no walls put up around you, your area of influence is a lot larger. That was really rewarding at Faraday. It took a lot of discussion with the founders and leadership, and everyone down to the engineers and designers, thinking about the market opportunity. The founder had a very clear vision of a space that was open in the market, where vehicles were not being seamlessly integrated with the technology that people use. It was very clear early on that this vehicle wants to be a super computer, and it wants to replace the cell phone when you get into a car. That's our credo. Even with a Tesla, people pull out their phone when they get in the Tesla, because the interface is what you're used to. It's more optimised for your daily life versus what's on your screen. That's the intersection we targeted. How do you create a vehicle that addresses that lack of integration? How can we bring the vehicle into the future in a way that's as easy to use as your cell phone? That's the impetus for the creation for the company. Lefteri: Do you think that statement of the "third internet living space" captures that? Beermann: If you're in certain circles, in certain parts of the world, that phrase is clearly understood. I'm not sure all people in the US are aware what the first and second internet living spaces are – which are home, and work, and so vehicle is the third. Lefteri: One last question. What would you most like to see at an event like the K Show, which is a plastics event; what would you most like to see from the plastics industry? Neuhauser: I would love to see the next level of tech integration catering not only to information screens but to active wellness screenings and sensory feedback between Human and machine, allowing the car to react and engage with its occupants though surfaces and generating a 2way path of communication. Modularity adaptability and self-healing surfaces would also be of key interest. And of course, the sustainability and eco conscious aspect of plastics of the future, showing directions to go full circle causing minimum to 0 waste, produced in a sustainable way with 0 or negative carbon foot print. How versatile can a plastic be? There's still lots of "greenwashing" going on and I would love more transparency. Where's the future of plastics going and what are suppliers actively doing to transition to that? Beermann: I'm equally focused on sustainability. It's not really clear which suppliers out there in plastics have the advantage. You have to do a lot of research in terms of who your best partner is going forward as you develop your product. It would be really interesting: could we have something like Leed certification, like you have for architecture, but for automotive and materials industry so you can understand who meets your needs and who doesn't? Who can allow you to create a five-star sustainable product? That would be interesting to me. I'm also interested in plastic alternatives. You have mycelium leather, cactus leather, there are also hybrids between that and plastics, you're using these natural products as substrate filler which can create all kinds of wonderful new hybrids which I’d be interested to see. Chris Lefteri More around Materials Design

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  • 20 years of experience in design innovations

    Interview with Alastair Curtis, Chief Design Officer, Logitech Copyright: Microstock_Growth 30.06.2019 Alastair Curtis is chief design officer at Logitech, where he is responsible for the designs of all business teams and brands. Since joining the company in 2013, Alastair is assigned to rethink and remodel all innovations of Logitech as well as to work on building, sustaining and promoting a design team and culture in the company. Alastair looks back on more than 20 years of experience in design innovations. Prior to Logitech, he was chief designer, senior vice president and head of the design department at Nokia. Alastair received his Master’s degree in Industrial Design Engineering at the Royal College of Art in London and his Bachelor of Science at the Brunel University. Alastair Curtis, Chief Design Officer at Logitech Chris: Logitech has one of the most distinctive, resonant, ambitious CMF and materials across its different products. How do you, as the guy who heads it up achieve that? Alastair: It was a relatively low-hanging fruit if you go back five or six years when I first joined. Logitech had seen phenomenal growth for thirty plus years riding the wave of PC peripherals in the early days and the explosion of people having a home computer, be it a tower or even a laptop. In that rapid growth, in the ability to ride that wave, Logitech had automized the machine to deliver incredibly reliable products, but they were, some-what, cost optimized to be reliable tools rather than emotional products. Whether it was conscious or subconscious, it evolved into a predominately safe portfolio of, and I’m simplifying, but black plastic . Obviously, the introduction of the smartphone, the introduction of the tablet had a huge impact on Logitech and Logitech's trajectory. Subsequently, there were some hard times and a reevaluation of the portfolio and a reevaluation of the company's strategy. Which obviously brought in Bracken Darrell as the CEO and myself in at Chief Design Officer. As we built out the design team, we started to have an impact of the portfolio. One of the key members of the team that I brought on was the head of CMF Katherine Pulford. She set about establishing a CMF strategy and how to apply color differently to our portfolio, but also starting to look at what new materials and finishes we could bring to the portfolio. So it wasn’t just about taking the mouse and taking it from black to red, but bringing silicones, bringing new materials and finishes to the products to bring about new experiences. As we started to establish a momentum, we then started to broaden the strategy across the whole portfolio and all of Logitech brands. Chris: You went from black plastic products to products like the UE BOOM that embody very tangible experiences, because of the materials. The BOOM for example for me feels more of an excuse to have fun on the beach, in the park, on the move, rather than just to listen to music it was also one of the early uses of textiles in consumer electronics. Using textiles was a pretty bold move. If you look at that time when we were getting momentum with the traditional sort of 'heartland' of Logitech – the keyboards and mice world, we were also just starting to get momentum with Ultimate Ears and the BOOM and the MEGABOOM which were using fabrics . At the time, the use of the fabrics was quite revolutionary in the consumer electronics space. I mean, now you kind of see fabric everywhere – Google, Apple across the board, but at the time the Ultimate Ears BOOM was quite a new product and it gave us a great canvas for color, and a great canvas for print, and for one-off graphics specials. The infusion of new materials and new colors in the keyboards and mice gave Logitech a huge amount of confidence about how it could start thinking about and talking about color and materials as part of its point of differentiation to the rest of the market and its competition at that time. Chris: So you have these speakers that are very dominated by color, textiles, soft-touch materials. Then you have mice which have a use of materials that tell totally different stories for different audiences. Where other brands might try to unify their products through a singular brand CMF yours are very individually targeted. Were you tempted to create a homogenous CMF for the brand? Alastair: We have high level design principles which apply to every brand and every category we have in the company, but when you sort of helicopter down, and come down into each brand, we were very conscious about maintaining authenticity and uniqueness of brand identity within that specific brand. So, it's not to say we didn’t necessarily use a certain color in multiple categories and multiple brands, but we were very conscious of maintaining a color palette specific to each brand. Chris: I think that it's quite a challenge for a lot of companies to integrate marketing, sales, sourcing into design and to understand the value of CMF and using unconventional materials. I know that from the organization point of view different teams at Logitech are very closely integrated. Do marketing embrace the whole CMF and materials approach? Alastair: You know, in some ways it's harder now than it was five years ago. That's not a critique of the people today versus five years ago. If you go back five six years ago, the company had gone through a very tough time and was more open minded – I'm trying to say that when you've been sort of humbled a little bit, you've gone through a hard time, you are more open minded to new ideas, new ways of doing things and new approaches. If you look at it from me coming in, it was a great time for me and the design team to come in and establish itself because there was no baggage, no history and the incumbency was ready for change. So we were a natural change agent. So introducing new colors and materials was not that hard actually. The sales regions were very open minded very welcoming to new thinking and freshening up of the portfolio. If you zoom forward to now, we review every brand, every portfolio on a weekly basis. Not every product that's live, but we'll deep dive on a specific product within each business group once a week. From the earliest sketch all the way through to final products and launch, we try and do those reviews not just as a design team, but we also call in part of our marketing organization. So they have visibility in the early days but they also have a means to input and, to a certain extent, co-create as we evolve from a blank piece of paper to final product. So it's a much more collaborative, shared process versus a, 'we do our bit and hand it over, and someone else does their bit.' Provide confidence in the tools Chris: Spotlight, which is the presenter tool, is another great materials case study. You created the product from researching the emotions people go through when giving presentations. I read that you studied how it feels to give a presentation, with even the most experienced presenters getting nervous. You used that research to drive a product that was going to change the way that the presenter felt about giving presentations. How did materials feed into that product to enhance that experience? Alastair: Yeah, the materials played a key part in many ways. I mean you yourself do lots of presentations and I do a fair chunk of presentations and however many you do, you still become nervous, there’s still anxiety depending on the number of people in the audience. When we started to design that product, it was clear that the more you can provide confidence in the tools, not just Spotlight, but all of the tools, that they are going to work when you want them to work, how you want them to work, it takes a chunk of the anxiety away. So when we were designing the product it was 'how do you make it as simple to use,' which obviously, we paired back the number of buttons to make it as simple to use but how do you make it feel solid, reliable and make you feel good through the premium-ness of the materials? Yes, we could have made it out of a beautiful plastic, I’m sure, and great finishes, but the coldness of the metal, the rigidity of the metal and just the perception of what metal brings as far as higher value – it may only be two percent, it may only be three percent but its just that little more confidence it gives the consumer when they’re using the product versus when they’re using anything else. Chris: Ok so you were bold in the way you were using textiles for the BOOM speakers but you were also pretty brave in the K780 keyboard which is a CMF icon and one my studio often use as a reference. It has also inspired many other products with the same effect. It was quite radical because you're using a texture that could potentially appear to be a flaw, and you have to get it absolutely right in terms of the density of specs, distribution and the color. Was that a challenge to get through? Alastair: When it was first pitched and proposed, it was quite a challenge and I think it's fair to say even though, as you said, its held up like a quite a key product from introducing the speckle and the CMF, in your words icon, it's also fair to notice that it’s not that color and it doesn't have speckles in every region. So I think in Europe it has the speckles, but in the US it doesn't have the speckles because the US market wasn't ready for speckles. They thought it would be too polarizing. So I think that probably indicates how challenging it can be to get something like that into the global portfolio. Using sustainable materials and sustainable processes Chris: I've heard some companies talk about the sense that there is an expectation from consumers of perfection in products. You can look at phones as an example of completely seamless products – there are no joints, no screws. What's interesting about the keyboard is that you could interpret that as a sort of a natural product where inconsistency in the flakes maybe shows imperfection. Do you think consumers are moving towards more of an acceptance of that kind of effect – when it comes to sustainability because maybe there are certain materials where it would benefit them not being so perfect and pristine? Alastair: If you ask me that about the consumer today, then I would say no, I think there still is an expectation of perfection driven by Apple over the past five, ten years. I think we have to change that and I think the consumer will evolve in their understanding of materials, evolve in their understanding of sustainably and the implications of sustainability. I think, if you ask me in five years time, in ten years time, I think the consumer will be having a very different perspective, I hope they will have a very different perspective. That's the challenge, I think, for Logitech – we discuss it a lot. At some point we may need to think about how we communicate that our product is using sustainable materials and sustainable processes versus the competition. Because if the consumer doesn't understand that ours may be more sustainable in materials and finish than the competition, they may look at our product as a lesser product because of that perfection dimension. It's almost not apples and apples as a comparison. How we do that? I think we've still got to look at and explore ideas. Its like food packaging – where food packaging now, you look at the packaging and it talks about the food inside, it talks about sodium, fats, fibers, etc, etc. So you have a sense of how healthy that food is inside the packaging. I wonder whether this idea from packaging is going to have to happen, within the consumer electronics market. It's going to have to play a role similar to that in the early days, where a consumer can hold a mouse against another mouse and see that, functionally, they are the same product but also then recognize that one is far more sustainable solution than the other. I mean, we are moving in that space. There will be companies who take a position and pioneer and drive towards more sustainable solutions and others will be slower, but the consumer won't recognize that, and we're going to have to work out how to, 'educate' sounds awfully patronizing, but make consumers more aware when they’re making those choices. Chris: What else can you share about Logitech's approach to the environment? Alastair: In general terms, we're incredibly committed to sustainability, and not just an abstract sustainability target, we have distinct sustainability targets which are aligned with goals beyond Logitech. We're looking at the Paris Agreement and other measures. We're looking at our complete footprint and handprint for the whole company, from our factories to try and make the factory carbon neutral, packaging and all the way down through materials. So it's not like we flick a switch and we'll go, 'okay, everything has to be fully recyclable material from the get go,' but we are committed to transforming the whole portfolio in line with our sustainability targets. Things like PVC cables, we've dropped three years ago. It's more about transitioning the whole portfolio from not just materials but how we may assemble them, how we may make them disassemble-able, so the full circular program. Chris: I have heard that at Logitech you are doing this not because we've done research that says your consumers want you to do or expect it, but actually, because you, ethically, feel that you should be doing it. Alastair: I completely agree, that’s why we've not really talked about it publicly at all. This is very much going up to Bracken going down to the leadership team across the board. It's a commitment to our future generations, it's not a commitment to making a more sellable product to the consumer. More around Materials Design

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  • Recyclable furniture from the creative workshop

    Interview with Pascal and Daniela Becher, founding members of plastikfabrik Exclusively for K-MAG Source: katalin gyurasics/Unsplash 24.01.2022 Plastic is a versatile material that can be used for a wide variety of projects. What's more, it is reusable and can be given new forms – so it can be given a second life in the sense of the circular economy. In the plastikfabrik in Saarbrücken (Germany), Daniela and Pascal Becher breathe such a second life into plastic. The two are convinced that innovative ideas can be created not only in large laboratories, but also in the private sphere – for example in the plastikfabrik. There they design new and practical objects from old plastic – and everyone is welcome to make a difference themselves in terms of the circular economy. Pascal and Daniela Becher; Source: plastikfabrik Please explain briefly what the plastikfabrik is. Pascal and Daniela Becher: The plastikfabrik is essentially a creative workshop. Here we develop recyclable design products from recycled plastic together with changing designers, artists, researchers and other people who are motivated to make a difference. We first test the products in small series to see if they are suitable for the market. Later, larger productions go to regional companies. Our goal is to get as much plastic as possible out of the linear system and into the Circular Economy – and to keep it there. How did you come up with the idea for this project? Becher: It was a process. Sustainability has played a central role in our lives for a long time. Then last winter we spent a lot of time at home – like everyone else. And that's when the decision matured to do more than just get our own CO2 mix in order. We did a lot of research and tried out a lot of different things. During our search, we also came across the global " Precious Plastic " movement. We were totally inspired by their approach. We are convinced that a future worth living for future generations on our planet cannot function without an efficient waste recycling economy. The plastic problem in particular is huge. Waste plastic litter our oceans, mountains and cities – the whole planet. And the burning of plastic also damages the climate. Yet plastic is basically a high-quality material. This is where we wanted to start, and so the idea of the plastikfabrik was born. How can you imagine working in the plastikfabrik – the word "factory" sounds like fixed structures and processes at first. Becher: The name plastikfabrik is definitely a term of art. Of course, we are not a large factory with huge industrial plants. But with our model we are entering an area that is primarily reserved for such production facilities. We don't have any fixed structures and processes. We are still a young project and find it exciting to play with concepts. But we also use classic prototyping methods such as digital 3D modelling, manual techniques, carpentry with jigsaws, routers and so on. We love working haptically with the materials. The prototypes are sometimes created at home, sometimes in a coworking space in the city of Saarbrücken, sometimes at the Hochschule der Bildenden Künste Saar (HBK). We are currently working on a cooperation project with students there. Among other places, plastikfabrik members meet at co:hub66, a coworking space in Saarbrücken. Source: co:hub66 What products do you design at plastikfabrik and what products are you planning to add in the future? Becher: We are on the move in interior design. For us, it is crucial that all products are always developed holistically in the sense of a circular economy. The plastic material consists of 100 per cent recycled material, the products are designed strictly with recycling in mind. The material remains pure, nothing is glued or similar. The products are always multi-use products, that means they can be used in many different ways. Broken parts can also be replaced. And at the end of the life cycle, we are happy to take the products back and recycle them again. One of our first products will be a modular seating system that we are particularly proud of. It consists of stools and a bench and is made as a plug-in system from recycled plastic sheets. This means that it remains unmixed and can also be freely combined. The stool can be a table, the legs of the bench can be used for the stools and vice versa, and so on. The "flat pack furniture" system also ensures environmentally friendly shipping; and if you want space in the house, you can dismantle and store it in a few seconds. In times of shrinking living space, flexibility is important. A 100 per cent recycling of the material is our top priority, and this is exactly what the current project with the HBK is aiming at. The offcuts that are produced during furniture production are used for other products; in the last step, the material is shredded and processed into new products using the injection moulding process. You are still paying for the project out of your own pocket - have you ever considered getting investors for the project? Becher: Of course. The project is a matter of the heart, we are not primarily interested in high sales. We really want to achieve something for environmental protection and also for people's green awareness! We would be absolutely open to talks with an investor who shares this mindset. What projects do you want to implement there in the future? Becher: We have many ideas for the future. For example, it would be super exciting to produce our own plastic records in cooperation with a record manufacturer. There is a lot of potential for creativity here! We also find a rental model appealing and are thinking about trying it out. There is already an end in the word "end customer" – and we stand for circulation! What do you want to achieve with your work in the plastikfabrik for yourself, but also for your environment? Becher: Our goal is, of course, to pull as much plastic as possible out of the linear system into a circular system. We are aware that our work here is only a drop in the ocean. Nevertheless, we would like to make a contribution to raising awareness about circular economy, recycling and environmental protection. In the longer term, we plan to offer workshops for schools and educational institutions to make knowledge tangible in practice and to inspire the next generation for this topic. After all, today's children are tomorrow's decision-makers. What role do you think the commitment of private individuals on the one hand and the commitment of industry and companies on the other hand will play in the future when it comes to linking the topics of plastics and environmental protection? Becher: Green awareness is increasing among the population, the topic of saving plastic is absolutely in line with the spirit of the times. In our opinion, private individuals can achieve a lot here. Social pressure is a driver for many companies to switch their packaging material to recycled material, for example, even though virgin material is much cheaper. The trick for consumers here is to distinguish truly sustainable products from greenwashing. But it won't work without the action of industry and business. They have the greatest power to be climate killers or future savers. Kyra Molinari (Editorial team K-MAG) More around Plastics in Daily Life

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Topics covered in K-Mag

Sustainability

Sustainability

Digitalisation

Digitalisation

Machinery & Production

Machinery & Production

Raw materials

Raw materials

Science

Science

People

People

Plastics in Practice

Plastics in Practice

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