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 (110)

  • Lightweight construction: customised thermoplastic fibre composite profiles enable more sustainable flying

    Interview with Dr Christian Garthaus, Managing Partner, herone GmbH Exclusively for K-MAG The start-up herone produces ultra-light thermoplastic composite profiles. Copyright: herone GmbH 12.06.2023 When flying, every gram determines the fuel consumption of the aircraft. To make air travel more climate-friendly, aircraft must become lighter. This can be achieved with components made of plastic, especially fibre composites. The start-up herone produces such. The special thing about them: They are thermoplastic fibre composite profiles with customised properties. The founding team from left: Daniel Barfuß, Alexander Rohkamm, Dr Christian Garthaus. Copyright: herone GmbH In an interview with K-MAG, Dr Christian Garthaus talks about the extent to which the composite profiles can be customised, what advantages this has and how the environment in particular benefits from it. Dr Garthaus, in 2018, you founded herone as a spin-off from the Technische Universität Dresden. How did that come about? Dr Christian Garthaus: After several years of research at the TU Dresden, my colleagues Daniel Barfuß, Alexander Rohkamm and I decided to bring our developments into commercial use independently for customers who were already interested. At that time, we had already been working for many years with well-known industrial customers who showed strong interest in industrialisation. This was the first time the idea came up. With the help of the EXIST research transfer programme of the German Federal Ministry for Economic Affairs and Climate Protection, high-tech start-up projects that involve complex and risky development work are funded. This programme enabled us to make the transition from research to self-employment. After six months, we then founded herone GmbH. You offer composite profiles that are tailor-made. What does that mean exactly? How do you achieve that? Garthaus: By customised composite profiles we mean the individual integration of additional functions directly into the component – during the manufacturing process. For example, our herone technology combined with the unique properties of thermoplastics allows us to integrate force-transmitting elements such as gears or threads made of the same matrix material directly into the composite component. This makes the component lighter and more robust and at the same time saves the number of process steps required and thus costs. By integrating standardised interfaces, such as the thread, we offer an easy way to use the components and thus to exploit the potential of the lead component. Where exactly are your products used? Garthaus: Our cost-efficient fibre composite profiles are used where loads, movements or liquids are transmitted and particularly high demands are placed on the material, such as pressure, temperature or force transmission. In addition to resistance, the components often have to be particularly light. This is particularly in demand in the aerospace, medical technology, sports or automotive sectors. Currently, our team of 13 mainly aerospace engineers and lightweight constructors is working, for example, on prestressed engine compartment struts and innovative hydrogen fuel lines for emission-free flying in the future. Basically, many areas of application are conceivable for our products. herone develops lightweight solutions for the transmission of loads, movements and fluids in various industries. Copyright: herone GmbH To what extent do your products contribute to more sustainability in these areas? Garthaus: Based on the automated processing of thermoplastic tapes in a braiding process and subsequent consolidation in an internal pressure-based pressing process, our herone technology can be used to produce thermoplastic composite hollow profiles in a resource-saving and cost-efficient way. These completely dispense with metals, but not with their advantages. Formerly metal connecting elements are made from the same thermoplastic base material, so that the composite components are completely recyclable. By using recyclable and recycled thermoplastic material, we are exploring new ways to close the material loop for high performance products. In direct application, for example as a tension-compression strut in an aircraft, our products contribute to fuel and CO 2 savings with weight savings. Every kilogram saved can save several tonnes of fuel over the life of the aircraft, depending on the aircraft. What are the biggest challenges in your work? How do you meet them? Garthaus: Anyone who wants to bring a product into series application in the aviation sector needs a lot of stamina and a stable, viable business model including well thought-out financing. As soon as the prototype developments are to be transferred to production, you need your own certified manufacturing facilities that meet aviation standards. In our case, this meant having a completely new production hall built while we worked with plant engineers to develop our special machines as a pilot line. During these processes, our entire team is confronted with new tasks and challenges every day. I think that with a good portion of courage, willingness to learn and a motivated, broad-based team, we grew into new areas together, piece by piece. What are your next goals? Garthaus: In the next few years, we want to get our developments "in the air to fly". In concrete terms, this means that we would like to transfer our projects into ongoing series production and produce aerospace components in large quantities. Parallel to this, we want to create the first series components outside of aviation, for example for sports and leisure, which should combine performance and sustainability. Elena Blume (Editorial team K-MAG) More around Mobility

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  • Design4Recycling: flat plastic bottle for sustainable wine enjoyment

    Interview with Amelia Dales, Commercial Director, Packamama Exclusively for K-MAG Copyright: Viinilinna, Aino Maaranta 11.07.2023 If wine bottles were designed for the first time today, they would look different – the British start-up Packamama is sure of that. Especially in view of the climate crisis, packaging needs to be rethought. This is how Packamama's flat plastic bottle came into being, which is not only highly sustainable but also makes quite a visual impact. Amelia Dales. Copyright: private In an interview with K-MAG, Amelia Dales talks about the advantages of plastic, the extent to which the flat wine bottle saves CO 2 and why this is particularly exciting for the wine industry. You say: "We took the wine bottle and made it better." What does that mean? Amelia Dales: We believe that wine needs better bottles – ones that are up to the challenges of the 21st century, first and foremost the climate crisis. Round glass wine bottles are heavy, spatially inefficient, high in emissions easily breakable and dangerous if they have shattered. If designing bottles from scratch, you would do it differently. In fact, you would create a bottle with the opposite features, which is what we have done at Packamama. Copyright: Margot Mchn Why did you choose plastic for this? Dales: We did not choose plastic, we chose the most scalable sustainable material available which is 100% recycled PET. No other available solution competes for a scaled solution at this time. We are clear in our communications when explaining our material choice and that starts with highlighting that plastic is an oversimplified term for a group of polymers that behave and perform very differently. This makes it hard for consumers and those that do not work in materials or packaging to have a clear understanding of what is good and what is not from an environmental and commercial perspective. We choose to use food grade rPET as it's a best-in-class material for our application; lightweight, robust, visible glass like properties, low energy required to produce, move, and recycle, and importantly the most widely recycled plastic in the world, contributing further to circular material use. In what way is your bottle more sustainable than conventional wine bottles? Dales: Our bottles are more environmentally sustainable because they are made from a lightweight material which takes more than 6 times less temperature to blow. By changing the shape and material, we offer wine companies a bottle that is on average 87% lighter and can fit up to double the amount of wine in most given spaces, such as on a pallet, on shelf and in the fridge at home. This significantly reduces costs and emissions through the often long and complex wine supply chain. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Round glass bottles and their associated secondary packaging and transport are the largest contributors to wine's carbon footprint and so this is the area where a significant improvement, or better bottle, can have the greatest positive impact. The wine industry is at greater risk than most from the extreme weather events brought about by global warming, which will become more frequent as the climate crisis worsens. Studies show that if we reach two degrees Celsius rise in global temperatures, over half of the current vineyard land would no longer be suitable for producing grapes for wine. The use of 100% recycled PET and the flat shape of our bottles allows wine companies on average to halve their carbon footprint. Copyright: Accolade Wines How can the plastic bottles be disposed of? Dales: One of the key elements in creating the Packamama bottle was to ensure recyclability by design. PET is easily and widely recyclable, in the UK 99% of local authorities provide kerbside collection. In addition, we recommend a specific cap, made from polypropylene, and labels, including appropriate wash off adhesives. Not needing to separate components and the use of mono, not mixed, materials is fundamental in making it simple and easy for consumers to recycle our bottles once they have enjoyed their wine. Therefore, we do not recommend disposal, but we recommend recycling. What are your next goals? Dales: With our current wine bottle format, we have offices and production in both the UK and Australia. Spring this year saw us launch a collaboration with closures giant Vinventions in France, and next we will launch in the US. In addition to growth across multiple geographies, we will also broaden our product portfolio this year to include a 750ml flat Burgundy bottle and a flat 187ml Bordeaux bottle. We are also active in studying bio-based materials or other potential novel materials of the future. Elena Blume (Editorial team K-MAG) More around Plastics in Daily Life

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  • Sustainability meets quality: new car tyre sets standards

    Interview with Kristina Kumme, formerly Product Manager for Summer Tyres, now Strategic Program Manager at Continental Reifen Deutschland GmbH Exclusively for K-MAG With Continental's new UltraContact NXT series tyre, sustainability and quality go hand in hand. Copyright: Continental 26.07.2023 Updated on 05.03.2025: We have revised this article to include the latest developments and provide the most up-to-date information. Sustainability or quality? This is the question manufacturers of plastic or rubber goods ask themselves when it comes to the use of recycled or bio-based materials, for example. Continental proves that the two can go hand in hand with its new UltraContact NXT series tyre. It consists largely of sustainable materials and impresses with high performance values. Kristina Kumme. Copyright: Continental Recyclability and Performance In an interview with K-MAG, Kristina Kumme talks about the environmentally friendly composition of the new tyre, its performance and Continental's ambitious sustainability goals. You presented a new tyre in mid-June with the UltraContact NXT. What is so special about it? Kristina Kumme: The UltraContact NXT is the most sustainable tyre that has been produced in series so far. It has a total of up to 65% recycled, renewable and ISCC PLUS mass balance certified materials: Up to 37% of the materials are recycled or renewable. More specifically, the tyre consists of up to 5% recycled materials , namely recycled steel, recycled rubber and polyester from recycled plastic bottles that do not come from closed-loop recycling. 32% come from renewable materials. In addition to natural rubber, the tyre contains, for example, silicate from the ashes of rice husks and bio-resins. These include, for example, resins based on residues from the paper and wood industries. The resins used in tyres make tyre compounds flexible and thus improve the material's adhesion. In addition, we have used up to 28% ISCC PLUS mass balance approach certified materials from bio-based, bio-cyclable and circular raw materials for the tyres. In the EU tyre label, the UltraContact NXT receives an A rating in all three categories tested (rolling resistance, wet braking and rolling noise). Copyright: Continental What Are Tyres Made Of? A Look at UltraContact NXT’s Composition What other features distinguish the tyre? Kumme: With the UltraContact NXT, we have not only significantly increased the proportion of recycled and renewable materials, but also improved the performance values: all sizes of the UltraContact NXT receive a Triple A rating in the EU tyre label and thus the best value for rolling resistance, wet braking and rolling noise. Triple A means that the UltraContact NXT has been rated A - the best grade on the scale - in all categories tested for the EU Tyre Label. The EU tyre label allows buyers to evaluate individual properties of tyre models and compare them with regard to the three criteria of rolling resistance, wet braking properties and external noise. Testing by the EU label is the prerequisite in Europe for placing a tyre on the market. The good values in terms of rolling resistance, wet braking and rolling noise also improve its sustainability in the use phase: the low rolling resistance also reduces the CO2 emissions of a combustion vehicle and increases the range of electric vehicles. The UltraContact NXT is made from 65% recycled, renewable and ISCC PLUS mass balance certified materials. Copyright: Continental Modern Tyres and Their Role in Sustainable Mobility What is the challenge in using recyclates or alternative raw materials for tyre production? Kumme: On the one hand, to obtain the materials in sufficient quantities from our suppliers and, on the other hand, to match the performance characteristics of the tyre at the same level or, for the UltraContact NXT, even at an even higher level. Intensive preparatory work was necessary for this, which already started in 2021 and was shown in the GreenConcept at the IAA 2021. We managed this on the one hand through close cooperation with our suppliers and through intensive exchange between all the specialist disciplines involved, from material experts to purchasing. Exhibitors & products around raw materials & auxiliaries Thermoplastics Thermoplastic elastomers Resins & compounds Foams & intermediates Fillers To all exhibitors in this category When and for which vehicle types will the tyre be available? Kumme: The UltraContact NXT is now available at tyre retailers across Europe and has been developed for both electric and combustion engines. It will be available for several popular vehicles such as the Kia Niro, VW ID.3, Mercedes-Benz EQA, Tesla Model 3, Audi Q4 E-TRON, Skoda Octavia, VW Golf 8, Audi A3 and many more. The NXT rubber compound contains natural rubber, recycled rubber and recycled PET bottles, among others. Copyright: Continental Continental Tyres: A Step Towards 100% Sustainability What are your goals in terms of sustainability? And to what extent have you come closer to these with the development of the UltraContact NXT? Kumme: By 2030, we are aiming for a share of over 40% of renewable and recycled materials in our tyres. By 2050 at the latest, all of our new tyres will be made of 100% sustainable materials. The UltraContact NXT is an important step towards achieving our sustainability goals and becoming the most advanced tyre manufacturer. Continental continues to meet its sustainability targets by constantly increasing the use of recycled materials for its car tyres. You can also read it here ! More about Tyre Recycling in our K-Mag Article! Elena Blume (Editorial team K-Mag) More around Mobility

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  • "Wonder Matter(s)" – Plastics at Milan Design Week 2023

    Exclusively for K-MAG Copyright: clodio 12.04.2023 Plastic is a wonderful material. It can take on almost any shape, colour and texture. This versatility opens up countless possibilities for designers. This is also proven by the exhibition "Wonder Matter(s)", which will take place during the Milan Design Week 2023 and in which innovative plastics will be presented in partly extraordinary installations. Milan Design Week will take place from 17 to 23 April 2023. Visitors to Superstudio Più can experience the interplay of design and materials in the exhibition "Wonder Matter(s)". This is organised by the consultancy Materially and aims to address the concept of wonder through a sensorial, experimental and narrative journey among materials with diverse composition and applications. One of these materials: plastic! At "Wonder Matter(s)", companies in the field of material innovation will present products that stand out for their high technical, sensory or environmental performance. K exhibitors Covestro and Asahi Kasei as well as The Good Plastic Company will also be taking part. The following companies will present their installations and innovations made of plastics at the "Wonder Matter(s)" exhibition during Milan Design Week: Copyright: Covestro Covestro presents Arfinio® With the installation "The Impossible" Covestro presents Arfinio®, a revolutionary material based on a new technology combining liquid high-performance polymers with minerals and produced by reaction injection moulding. It is a lightweight and durable solid-surface material that allows complex projects to be completed easily and quickly in a single step. It can also be repaired and recycled. Arfinio® combines the advantages of aliphatic polyurethane chemistry, reaction injection moulding and solid surfaces: a combination that was considered impossible for decades. Learn more: www.covestro.com/arfinio We already reported about Arfinio® in K-MAG. Click here for the interview with Covestro. Copyright: Covestro Covestro presents Makrolon® RE Another Covestro installation is the "Unexpected Green Forest" – a place of oxymorons where plastic proves to be more sustainable, recyclable and durable. The installation is dedicated to Makrolon® RE. This is a renewable polycarbonate made from raw materials derived from organic waste rather than fossil fuels. The material not only supports sustainability goals, but offers enormous creative possibilities in terms of colour, shape and decoration. Learn more: www.covestro.com/makrolon Copyright: Covestro Covestro presents TPU Finally, Covestro presents thermoplastic polyurethane (TPU) in the "Selfie Garden", a playful installation. The material has a broad and articulated performance spectrum that includes a high degree of flexibility and temperature resistance. Its properties make it an excellent material for monomaterial design. The adaptability and multiple applications of TPU become an inspiration in the design of an imaginary garden. Of course, the selfie garden also provides a perfect backdrop for a souvenir photo. Learn more: www.covestro.com/TPU Copyright: Asahi Kasei Asahi Kasei presents RespiGard™ by Polypore RespiGard™ by Polypore is a waterproof and breathable polypropylene membrane presented by Asahi Kasei. The material can be combined with fabrics and offers applications for outdoor furniture and technical sportswear. The membrane's high porosity allows airflow and easy evaporation of moisture, while its structure prevents water droplets from penetrating. RespiGard™ is water repellent, has a smooth and even surface and is ultra-lightweight. It is produced using a solvent-free manufacturing process and has therefore received OEKO-TEX® STANDARD 100 certification. The base is made of polypropylene and is recyclable. Learn more: www.polypore.com/RespiGard Copyright: The Good Plastic Company The Good Plastic Company presents Polygood Polygood is a surface material made of 100 percent recycled and recyclable plastic presented by The Good Plastic Company. In addition to its sustainability, the material also impresses with its aesthetics. Each pattern has its own unique background story. The Polygood panels are made from a wide variety of plastic waste – from refrigerators to disposable cutlery and electronics to industrial consumer goods. The Good Plastic Company aims to bridge the gap between the recycling industry and the economy. Learn more: www.thegoodplasticcompany.com "Wonder Matter(s)" 17-23 April 2023, Superstudio Più https://www.materially.eu/en/the-matter-of-emotions/exhibitors-2023 Elena Blume (Editorial team K-MAG) More around Materials Design

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  • With the power of the sun to the mobility of the future

    Copyright: anatoliy_gleb 20.07.2023 In front of numerous guests and with great public attention, Team Sonnenwagen presented its new solar racing vehicle Covestro Adelie at the Eurogress Aachen, Germany. Over the course of one and a half years, the 50-member team of students from RWTH Aachen University and Aachen University of Applied Sciences created a new car model based on interdisciplinary research and extensive experience. This gives it a good chance of successfully participating in what is probably the world's toughest solar car race – the Bridgestone World Solar Challenge from October 22-29, 2023 in Australia. Covestro shares the enthusiasm of the students and supports the team with innovative material solutions, technical exchange and as main sponsor. "For me, the Sonnenwagen is a powerful symbol of future mobility, because it shows us that we need to ask crucial questions about materials science and design on the way there," said Sucheta Govil, Chief Commercial Officer at Covestro, in her welcoming speech. "For me, the Sonnenwagen team are exemplary for creativity and entrepreneurial spirit. The students proved an impressive motivation and know-how to develop and optimize new ideas for solar-powered, light-weight electric vehicles." Multidisciplinary team Sucheta Govil, Chief Commercial Officer of Covestro (left), Lina Schwering, 1st Chairwoman of Team Sonnenwagen, and Oliver Krischer, Transport Minister of North Rhine-Westphalia, are pleased with the successful presentation of the new solar car. Source: Covestro As many as nine disciplines of the Aachen-based team were involved in the design: the chassis, aerodynamics, structure, electrical engineering, driving strategy, production, sponsorship, marketing and logistics departments. "Close and efficient cooperation between these areas is very important, because we want to compete in the Challenger class at the race, where the main focus is on performance and maximum energy efficiency," explains Lina Schwering, 1st Chairwoman of Team Sonnenwagen. "A lot of working time has gone into the Adelie, which we have invested alongside our studies and during our free time, and a lot of commitment and heart and soul." In total, more than 50 teams from 24 countries are setting out on the more than 3,000-kilometer route from Darwin to Adelaide – right across the Australian outback. There, people and models are exposed to very harsh climatic conditions with high temperatures and strong UV exposure from the sun during the race, but also during the preceding test drives. In addition, the vehicle is subjected to strong mechanical stresses that can affect the efficiency and performance of the battery. Innovative materials Object of desire – in front of numerous guests, Team Sonnenwagen's new Covestro Adelie solar race car saw the light of day in Aachen, Germany. In October, it is scheduled to compete in the Bridgestone World Solar Challenge, the world's toughest solar race in Australia. Source: Covestro "The Sonnenwagen team therefore needed a lot of support in selecting the materials," says Andreas Brandt, Head of Group Marketing and project sponsor at Covestro. "The new Sonnenwagen incorporates innovative products with different functionalities from various business segments, which are tested under track conditions." For example, the aerodynamic outer shell was made from milled SikaBlock® polyurethane foam blocks from Sika, a long-standing partner of Covestro and another sponsor of Team Sonnenwagen. The Leverkusen-based company provided raw materials for this and advised the team on the implementation. The Sikaflex® sealants for the solar cells are also based on components from Covestro. Other examples include a plastic sheet made of polycarbonate for the battery enclosure and thermoplastic cushioning materials for the driver's seat trim. "Pushing boundaries is what we at Covestro have in common with the young talents of Team Sonnenwagen," says Sucheta Govil, summarizing her message. "We push the boundaries of innovation in materials, driven by our commitment to sustainable mobility of the future. With our products and solutions, we materialize the circular economy." Source Covestro AG More around Mobility

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  • Better recycling of plastic packaging: New process extracts fragrances

    Copyright: evgrafovasa 04.05.2023 What doesn't smell good is hard to recycle. This simple rule also applies to the growing volume of plastic waste worldwide. One way to recycle it in an environmentally compatible and climate-friendly manner as high-quality post-consumer recyclates is through improved sorting and reprocessing. Until now, the reduced material quality has considerably limited the reuse of plastic recyclates, and this is mainly due to their odor. Scientists at the Fraunhofer Institute for Structural Durability and System Reliability LBF have developed a new environmentally friendly process on a laboratory scale to remove odors from plastic packaging. The new process is based on pressurized water extraction. It removes the tracer fragrance limonene from commercial HDPE packaging and does not require organic solvents. This reduces costs and protects the environment. In this way, the material quality of processed plastic waste can be significantly increased within one hour. Common HDPE packaging for cleaning agents. Source: Fraunhofer LBF The in-process analysis is based on infrared spectroscopy and mass spectrometry that provide the research team with data on the chemical composition of the samples as a function of different extraction conditions. The analytical data show that significantly less limonene is present in the samples after extraction. Furthermore, in addition to the fragrance, other impurities and short-chain HDPE are removed from the samples that were originally contained in the packaging. Based on these analyses, the Darmstadt experts determined the optimal process parameters for pressurized water extraction of fragrances from HDPE packaging. "The project results demonstrate the benefits of a systemic approach to solving current plastics technology issues with great social relevance," emphasizes Dr. Guru Geertz, who oversees the project at Fraunhofer LBF. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Material analysis with machine learning methods optimizes extraction process Principle of the multivariate analysis of a set of FTIR spectra. The color scale corresponds both to the intensity and the percentage of HDPE and the extractables (odorants, impurities). Source: Fraunhofer LBF To develop the process, detailed insights into the chemical kinetics of the extraction process were necessary, which were made possible by a novel approach for in-process analytics: Evaluating the data with the aid of machine learning methods was the key to optimize the extraction parameters in terms of the desired economical process control. At the current stage of development, an application scenario for the new process is emerging for the improved treatment of plastic waste: "The extraction process we have developed shows a way to reprocessed single-use plastics with an increased range of applications, and this serves to protect the environment," says Dr. Geertz. Due to the underlying concept, the process is equally suitable for industrialized, emerging, and developing countries, so that all market participants who bring plastic products into the trade can potentially benefit from it. The project was funded as part of the Fraunhofer-Gesellschaft's internal programs. Source Fraunhofer Institute for Structural Durability and System Reliability LBF More around Packaging

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  • Innovative fiber technology could revolutionize building construction

    "Winding" houses instead of building Copyright: FibR GmbH 17.08.2023 With the Texoversum, Reutlingen University has put into operation a training and innovation center for the textile industry that is unique in Europe. The almost 2,000 square meter textile-like façade of the new building also causes a sensation architecturally: It charmingly combines the innovative power of this industry with the 160-year tradition of Reutlingen as a textile location. The highlight: The components were wound from fibers that are fixed with a special plastic resin. The façade of the Texoversum is just one example of a brand new technology that could completely revolutionize the construction industry. The sophisticated structure was designed on the computer and is based on carbon fibers wound by robots. Similar to networks in nature, for example in spider webs, beetle wings or palm leaves, the fiber structures are also very lightweight, but at the same time highly resilient, and require very little material. This not only saves resources, but also facilitates transport and assembly of the components. The Texoversum at Reutlingen University is a reference object for a new technology that could revolutionize the construction industry: The components of its façade were wound from fibers and fixed with Covestro's Desmocomp® system. Source: FibR GmbH With the Texoversum, Reutlingen University has put into operation a training and innovation center for the textile industry that is unique in Europe. The almost 2,000 square meter textile-like façade of the new building also causes a sensation architecturally: It charmingly combines the innovative power of this industry with the 160-year tradition of Reutlingen as a textile location. The highlight: The components were wound from fibers that are fixed with a special plastic resin. The sophisticated construction was designed on the computer and is based on carbon fibers wound by robots. Source: FibR GmbH The necessary strength and durability of the composite is provided by Covestro's aliphatic polyurethane resin system Desmocomp ® , in which the fibers are embedded as if in a matrix. "The resin is highly resistant to weathering and the sun's high-energy UV radiation, making it very suitable for outdoor applications," explains Pejman Norastehfar, architect and specialist for construction applications in Covestro's Coatings and Adhesives segment. "Other plus points in the construction sector are its excellent chemical and flame resistance." In the Texoversum, the spun façade performs several important functions at once: it gives the building a unique look and stabilizes the surrounding balconies. It also serves as a railing and provides the necessary shade for the glass front behind it. The building provides approximately 3,000 square meters of space for workshops, laboratories, a textile collection, think tank space and classrooms. The costs for the construction of the Texoversum amounting to 18.5 million euros were borne by the employers' association Südwesttextil, whose members include FibR GmbH in Kernen, east of Stuttgart. Quelle Covestro AG More around Plastics in Daily Life

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  • “Europe Sets the Tone for Global Design”

    Chris Lefteri interview with Kiwan Nahm Exclusively for K-MAG The Objet collection was designed to be space-centric and fit into an interior environment in a seamless and non-competing way; Copyright: LG 07.07.2025 In a compelling conversation with material expert Chris Lefteri, Creative Director Kiwan Nahm reflects on the evolving role of materials, colors, and finishes (CMF) in modern appliance design—and Europe’s pivotal influence in shaping these trends. As appliances move toward minimalism and emotional resonance, Nahm argues that while LG translates global currents into its own design language, the original sparks—the “trend streamers”—originate in Europe. This exchange explores how LG blends inspiration from European exhibitions and lifestyle cues with its commitment to simplicity, artistry, and cultural reinterpretation—revealing a broader narrative of global design dialogue in the plastics era. As part of the Objet collection, LG’s Mist Beige colour range was developed as an alternative to traditional bold metal tones. The resulting ‘mist metal’ effect is softer and fits harmoniously into any interior environment. ; Copyright: LG Chris Lefteri: So, Kiwan, tell me what you're doing in Germany, tell me a bit about your role. Kiwan Nahm: I am officially the creative director of LG Europe Design Lab. My primary mission is to derive something for Europe, which means LG has a vast range of portfolio in different appliances or devices and all the electronics products. Specifically, Europe has a special sort of character in regards to lifestyle and custom preference. Therefore, we think it's important to create products that are really well perceived in the European market. In other words, we cannot sell the same product which is sold in the US to the European market because it's a completely different market. It is my mission to find out and analyze what's different in Europe and then transfer that into a design language that we can actually blend into our products so that it’ll be well received in the European market by the customers here. Chris Lefteri: That's very interesting. The reason I wanted to interview you as a designer from LG is because, if I look at the appliances that LG has been commercializing over the last few years since 2022, maybe 2021, I would say that they are very important, inspiring, CMF-leading products. For me, I look at what's coming out of Europe and all the other European appliance brands, and you really are giving them a run for their money. I mean, it’s almost like, “Wake up guys, let's move away from steel and white!”. It's interesting that you feel that you want to learn from Europe and actually take something or do something local, because it's almost like you're doing so much more interesting stuff in Korea! Kiwan Nahm: Even though LG has been able to create something that attracts attention, and propose some emotional values in purchasing products, we find the origin of the trend is usually from Europe. We're looking at different trends or lifestyle exhibitions in Europe so that we can get inspiration from them. We then eventually translate that into our own design language. But the ideas, and the hints, what we also call the trend streamers, I think those are still coming from Europe. And Korea is one of the cultures which can well interpret that into our own movements, into what we’re doing. For instance, cosmetics, fashion, entertainment, design itself, it's all originating from Europe. Also, one of the reasons is that products, in terms of their physical appearance, are getting more and more minimal. We're trying to hide things. We’re trying to hide whatever is unnecessary to see and feel. And then, because we're hiding everything, it is important that we have something that can serve as an appearance factor, something that can appeal, and so CMF will be one of the best tools to express that, a design that well displays the CMF, the kind of materials we're using, what colors and textures we're using, and that a product has to become more and more minimal. The minimal design tendency is also coming from Europe, I think, because let's say, for instance, in Germany, where I currently am, the Bauhaus spirit is to hide everything, all the way down to the least functional sort of detail needed. Other than that, we're trying not to be too decorative, we're trying to become more natural. In that sense we can get a lot of inspiration from European furniture, spaces, interiors. There are also various creative minds in Europe who have the same philosophy. So, it was interesting to experience all that and that's also one of the reasons why we think it's important to have a station in Europe, to find that out as soon as possible and as closely as possible. Yes. So, when you're trying to bring these European trends into LG's products, you talk about the LG design language. Is there a very strong CMF design language at LG? Nahm: I would say it depends on the product, and the character of the product, that we have as projects, because there's always a purpose for each product. For instance, there are products that have to give luxurious premium satisfaction, whereas there are also products which will be more functional and provide value versus the price paid for it. It depends on the mission or the purpose of the product but I think in general there's a minimum bottom line of quality above which CMF has to be standing. We cannot go lower than that or we should stay in this sort of quality range – it could be an emotional quality, or it could be a physical quality – so that we can provide at least this standard. I guess, if I'm right, you have these different sub-brands, like LG Objet and LG SIGNATURE, so these are very different in the way that they appear and their stories in terms of the CMF. And I have to say that the SIGNATURE sub-brand is obviously the premium one, but I see that kind of quality in many of your products. I mean, for me, it's always delivered very well. Nahm: There's this cascading effect which means, for example, with the origin of SIGNATURE, the idea was to launch a product which was not just premium; in fact, we've been calling it “hyper premium”, which is to say something which is beyond premium, but that doesn't mean that we have to use the most expensive materials or finishes on the product. Instead, we ask ourselves: how can we actually provide something which is more premium than what's in the market? And we kind of had success because SIGNATURE was a really good blend of stylish design but also the usability has been smart enough to compete in the market during that time. And since the success case of SIGNATURE, we've been able to cascade everything that's good in SIGNATURE into each appropriate product price level or brand tier meaning the cheapest refrigerator of LGE from the time before SIGNATURE is far different from the affordable ones that we're selling right now. There's probably a few years’ gap, but I think within that gap, the existence of SIGNATURE made a huge difference, because it made us build – or even transform – the most affordable ones in a more quality-oriented way. So I guess SIGNATURE, as that premium sub-brand, the top premium sub-brand, gave the organization confidence to then apply some of that to different products and also create subcategories below that? Nahm: Right, so SIGNATURE has actually pulled up the standards of quality in all line-ups for the LG product portfolio. SIGNATURE started out as home appliances mainly and then there was also the television and all the other product ranges, so it was spreading out 360 degrees to elevate the overall design quality. Very interesting. And then LG Objet is the more lifestyle-focused one? That came next, is that right? Nahm: We planned to make the Objet collection more space-centric, more lifestyle, more interiors-focused, physically speaking. Internally, we initially called it Space Fit, which means that, dimensionally speaking nothing just pops out or interrupts the balance or the flow. And then because there are a lot of different styles in the interiors, or different lifestyles, we thought it would be interesting to give them some customizability to edit someone's own taste onto the surface of an appliance product that's sitting there, which after all are not small-sized ones. It’s very bold. These are not quiet objects. Nahm: It's a huge, huge mass of electronics sitting in your space, right? From fridges to air conditioners and air purifiers, I mean, anything which is a title appliance is relatively big, quite incomparable. It’s almost the size of furniture. Right, but then rather than doing something that would be very safe and very neutral, you did something that was really “in-your-face” – lots of colours, lots of patterns – and that was quite a big risk because you don't make something for the masses, you make something that's very bold and very decorative. I'm thinking of the air purifiers, these little coffee tables, it's almost like a piece of Memphis in your living room! Nahm: I mean, if you look the other way around, let's say refrigerators. The refrigerators before Objet collection used to be white, or metallic, or even black, or something with reflective glass surface, something expressing a huge presence in the space. I mean if you like it, that's okay. But if you don't, if there's anything you don't like, in terms of the surface of the refrigerator, it's a burden to have that sitting in your kitchen. It's basically a huge tank which you don't like that much or maybe you liked it before but now you don't anymore. In that case, you want to have something that's more harmonious sitting there, something that blends well with the furniture or any other installments in that space. The term Space Fit also meant, from a CMF perspective, to be able to apply materials, colours, and all the finishes that are compatible or that blend harmoniously with the interior materials. I’m thinking about when we implemented the matte surface, the satin finishes, so that it's not glossy anymore. It's not pretending to be a hero of the kitchen anymore, but it blends into the space well, it still has a certain presence because it's got this ratio to the size sitting there. It still takes a lot of space in your kitchen, but it feels more friendly. It feels more subtle. And it feels more like a furniture rather than just a cooling tank. LG has developed a range of matte and glossy finishes, each specifically designed to complement a particular colour hue, creating a subtle yet striking effect; Copyright: LG I guess it must have been very hard to get that through, to LG as a company, to persuade the managers that this was a chance worth taking? Nahm: It's always a matter of supply chain management if you try to launch various CMFs in one single platform, so it was a huge challenge for us too, but the way to persuade the stakeholders is that we were not trying to launch twenty, or fifty, or hundreds of different colours and finishes all at once. We kind of concentrated them into very essential tiers. For instance, there will still be users who would want something calm, something not distracting, but still want something that has a sort of premium appearance. So, in that case, we actually provided very subtle beige natural warm colour ranges with smooth textures. But also, there are users who would still want metals, so we try to avoid using glossy reflective hairlines which have been sitting there for centuries, and just try to change the surface with a very satin calm muted effect, but that still has this least metallic sort of resonance. We call that “mist metal”, as if we sprayed some mist spray on the surface of the metal so it just reflects very smoothly. That's very interesting, because when I was at IFA last September, I noticed that you offer different types of mattes, it's not like there’s just “matte and gloss”, but actually there are different levels of mattes. And it's quite clearly promoted in the branding. Nahm: That is true because – I mean, you're the CMF specialist so you're quite well aware with this! – there are different glossiness levels. And, on the other hand, matteness levels. For instance, a certain specific matteness would fit well with brighter hues and brighter sort of effects whereas on the other hand a less matte level would actually suit more the darker ranges and so on and so forth. So, we cannot just unify everything to have this certain level of matteness or glossiness. So, we try to play with the small details so that they can make delicate difference. Even though we're talking about this, there are also not that many sort of variants in the matteness, because we classify them into very small numbers of levels so that we can actually manage to provide those effects in an efficient way. Yeah, but it's clearly communicated in the marketing of the product as well. It's not subtle. Nahm: Yes, it's necessary because there could be customers who would just be anti-matte or anti-glossy and there could be people who are in the middle – this is not that glossy, but still it’s got the boldness of glossy. Another person on the other hand, might be like, this is as matte as we can get, it's all muted, it’s what we call the set and finish. That's also how to persuade the customers when they're looking for new products. LG’s Mood Up range has brought new levels of customisation to the user, allowing for a change of colour and therefore experience, at a touch of a button; Copyright: LG Yes, and consumers are very perceptive now, you know… everyone's curating their own interiors. So, they're very sensitive – like you said – to different matte levels. It’s not just “matte and gloss”. You mentioned earlier something to do with feeling and CMF and things feeling a certain way. And if I look at, let's say, the fridge that you worked on, which is called Mood-Up, it's very explicit that it's about feeling. So, is this very intentional and strategic, this idea of making your customers feel a certain way about LG products? Nahm: The Mood-Up was first produced as a conceptual design markup… we had internal reviews and it was quite polarized because some people were thinking it was too much to have LEDs installed underneath the surface of a fridge. But others were saying, this is the ultimate version of Objet collection because the colours are almost infinitely customizable as opposed to certain ranges, which you cannot change that easily afterwards. Eventually, it was selling quite well and we were actually producing more than initially planned. There was one time when we tried to turn on the Mood-Up colors so that it could look like an aubergine collection – the combination of dark green and beige. We played around with the LGB and there were people not able to distinguish which is the real six screen printed glass panel and which is the Mood-Up design panel. So, it can actually mimic the real physicality of a CMF solution. On the other end, with high luminosity, it can also serve as mood lamps or mood-making lighting features just like in RGB LED speakers and things like this. It's quite versatile and I think there's still a big possibility when our designers will play around with different RGB numbers on that platform. When you were working on that, was it very hands-on, very experimental? Was it very playful for you as a designer? Nahm: Yes, it was very interesting to notice, “Oh, this could be very physical but this could be also very digital.” It it was interesting to play around with phygital CMF for the first time in my career. It was very fun, very interesting. And I thought there is something about the future of CMF in this because it's variable CMF. It's not something you have to change panel by panel. It's something you can just play around with the numbers through your application. It becomes a different physical solution. You know, for instance, like the holographic images in the Blade Runner films or anything like that, something which is virtual but precepted as physical? OK, I want to talk about another product, the Universal UP kit? Nahm: Oh, yes. Because that's also a really bold, and a very assertive, very forward-thinking, very culturally-relevant project. How did that come about? Nahm: Not just because we were trying to do the UP kits, we've been going through all our products currently in the market to find out how we could actually upgrade everything. Since software is very easy to be updated, like all the OSs and applications, they're updated on a few month basis, so we were thinking, is there anything we could do with the physical thing, maybe an UP kit or an add-on or maybe a replaceable sort of feature, that would be interesting? And we also thought it would be interesting and essential to become more barrier-free, which means from an ESG perspective, from a social sort of responsibility, how can we actually support all the customers, and not just a few? How could we actually evolve the product that we are selling in the market or even the ones that we already sold in the market? And since we've been using consolidated platforms for the same refrigerators, washing machines, we're using the same mechanical units, physical parts, so wouldn't it be great to launch UP kits or add-on kits so that we can actually propose more values and provide more services in that way? And I guess the colours as well popping out? So, people can see the colours? Nahm: I mean it was becoming more visible because we've been trying to hide everything. We're basically trying to be as intuitive as possible. The modern-day trend is to be as minimal as possible but there are also people who wouldn't feel very comfortable with that. The thing is, if you're using the UP kits, it's more visible. It's becoming more intuitive. It’s sort of a boosting accessory so that everybody will eventually be happy to use it. There are also users who actually do not have the difficulties in everyday life but still want to have these accessories so they can actually play around with it. It has become more of a helping item but also an item to pursue a certain satisfaction. So, if I understood it correctly, it wasn't just about inclusivity, it was about any user, whether they had disability or not, being able to upgrade or update their products through these accessories, is that right? Nahm: Yes, it started out as a barrier-free sort of approach, but eventually has become something more upgradable. Upgradability and physicality, but not too difficult. Something very easy, very intuitive, and rather more playful. Great. The last question is a very simple question, just to end the interview, which I ask everybody, and it touches on this idea of materials and emotions and memories, which is something that most people, or certainly a lot of designers, don't tap into. And the question is: what's your strongest memory of a material from your childhood and why? Nahm: From my childhood? I think it is both the time when I had the pleasure – but also the suffering – from one same material! I was playing around with a very strong, the oil ink-based marker pen. Yes. It’s a very strong. I was playing around with it at home, maybe I was like five or six. And then at that time all the fridges in Korean homes were either in ivory or military-like khaki green colors. Ours was green and I thought, maybe I should draw something on that fridge door! So, I was drawing graffiti on the surface of the refrigerator and I really liked it because if you draw something with a marker on the paper it just spreads out or it smears around and you don't feel that clean when you're playing around markers on the paper. But on the PCM or VCM – the pre-coated metal panel on the fridge door in the early 1980s – that was something I loved to draw on. That's the material, right? It's not the pen. It’s the pre-coated metal panel on the fridge door? Nahm: Yes. But mums do not like kids messing around with markers in their homes, making a crazy sketchbook out of a refrigerator door! And so my punishment was to erase all that using cleaning liquids and it was really hard to erase them so my experience with this material was like: “I love to draw, I love to sketch on a painted metal surface, but I really hate to erase that thing!” You were born to be a CMF designer. You wanted to colour in the fridge. That's what it was! Nahm: From that moment on, maybe I was destined to become a CMF designer for appliances. Yes it was, from that day! So, Kiwan, thank you very much for joining me today. Author: Chris Lefteri | K-Mag Chris Lefteri is a materials expert, author and industrial designer. Since 2006, he has been advising companies worldwide at the interface of materials innovation, CMF and design strategy. His books and lectures shape the global discourse on the conscious use of materials in design and industry. In K-Mag, he writes about the role of materials as drivers of sustainable product innovation. More about Plastics in Daily Life

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  • "Materials have the power to move a lot of things"

    Thilo Brunner, Chief Design Officer at On Running, in conversation with Chris Lefteri, Chris Lefteri Design Exclusively for K-Mag Copyright: ON Copyright: ON Chris So, Thilo, tell me about the design philosophy at ON that you have built. Thilo It’s a kind of Swiss philosophy, continuing a historical journey that Switzerland and industrial design have had for many decades. I always see it as a bit of a triangle where the functionality is at the very bottom, sustainability is in the middle, and on top is the styling. We've never been a brand that starts out with: How could we style things? But as you would expect from a Swiss brand, we started from functionality and materials, and the processes with which we can make things. I guess it’s mixed with the personal belief that materials and processes will define design more and more over the years because the technical understanding is just the base of the tools that designers need to work with. Chris So, would you say, you are one of the very few ‘materials first’ company? Thilo I would say we're an innovation-first company. To question and to scrutinise the status quo, whether it be in sport or in technology, materials, or process, that's something that's always been very, very important to us. For me, probably, functionality is really the base, but then comes sustainability. I think this question of how we can take the next steps in sustainability, whether they're small steps or continuous steps, or giant leaps, for me that always has to do with sustainability. I mean, we need to get better as an industry, we need get better as a consumer, we need to get better as a company. Copyright: ON Chris And was that something that you started at the beginning? Was sustainability always a key part of this? Thilo As it goes with start-ups, you have one thing that you focus on. To be very honest, being a small player in the beginning of this journey, you have to make sure that the shoes feel great, you have to make sure that they provide a certain sensation, but you have to also make sure that they do not fall apart, which in the first few months and years, only having access to a certain set of suppliers and to a certain set of people, was extremely important. I think it's correct to say that sustainability over the years became a bigger and bigger topic, once we figured out how the shoes mechanically work and prove that they can live a long life. Chris The subscription based, easily recyclable shoe Cyclon seems to have been developed pretty early on in the company? How quickly would you say you made sustainability a key focus? Thilo Well, ON started in 2010. And then of course, it depends what you count as the smaller and the bigger successes. There are continuous improvements that have been made over the years that still need to be made. And then there are – which you probably could read from the press – the bigger bets such as Cyclon or, as seen in the Paris Olympics, the Lightspray project where shoes are assembled through spraying and they're not stitched together anymore, where the exploration of the manufacturing process brought a new lens to so many topics, sustainability being one of them. Copyright: ON Chris The Lightspray shoe started as a very cool experimental project but you've managed to commercialise it. There are a huge number of innovations out there but actually for a big organisation to commercialise real innovation is very unusual. You did an amazing job of turning that into a mass-produced shoe, as you also did with the Cyclon. How as an organisation have you done that? How have you managed to keep that innovation through to production? Thilo The main way to measure the success of something like this is, is if you are able to scale it. That's the big nut to crack. I think innovation in a protected setting is always easier. But then if we're speaking about 100,000 or millions of products being made, that's a harder bar to reach. And yes, for Lightspray, the first model now is already commercially available. Chris But I still come back to this point that it's very difficult for companies to even take the risk, right? How, as an organisation, do you do it? How do you say, let's just try it? Let's take that chance. Is it a design decision? Is it the CEO? Thilo No, it's not only a design decision, but I would say in comparison to many other companies, design definitely has a seat at the decision table. And when it comes to innovation, frankly, this model of innovation and taking risks, this is something that you have to engineer very, very consciously. It takes a certain discipline to keep innovation going at all times. Sometimes you have these situations where it would actually be quite easy to work with known manufacturing methods and enjoy what's possible right now. It's quite hard to have the discipline to take the risk. Copyright: ON Chris It comes across that you have this cross-business, cross-functional collaboration with engineering, with sourcing, that everybody is on board with this focus on innovation and embracing new technologies. Thilo I'm very happy to hear that! Chris And also marketing. They seem to understand it very well. The value of storytelling for sustainability, for materials etc. I want to ask you about the Cyclon because this was also a very inspiring project and the fact that it's commercialised I think is another significant achievement. How is that going? Thilo I always like to talk about several things in the Cyclon model. So, it's a subscription. The subscription comes in one colour, white. Chris And that colour is so that you can upcycle it, right? Thilo Yeah, I mean, it's optimised to be as circular as possible and the only colour you can buy is off-white or even mixed whites because this is what is needed to make the process work. So what I like about the Cyclon is that it's a bit like a mirror of where we are not only as an industry, but as well where the consumer stands, because it's always one thing to take a certain stance as a manufacturer, but it's also about educating the consumer that some things might not be possible anymore if you think things through in a very radical, environmental way. I think what we need to learn is that I still believe we're not only in an industry but still in a phase of the world where in terms of production we still somewhat mimic the 1950s and the 1960s when people discovered plastics and everything was possible and everything became very colourful, and suddenly people had the freedom of choice that every product they can buy, they can choose from ten colours, etc (I’m making a bit of a caricature here). What we're discovering now is that we're looking into working with a completely new set of materials which are still rapidly evolving, which is not perfect yet, but I think what the consumers want, and what the producers want in the meantime, is very, very clear. What I'm not convinced of is that we still should continue to mimic the production and the consumer behaviour of the past. But we have to work around a new aesthetic, which as you know very well, I started to call “the aesthetics of sustainability” at some point, which for me is the symbol or metaphor of a new understanding of materials. Copyright: ON Chris That's a very bold aim to say that you want to change the historical status quo of consumer expectations, which is You can have anything in any colour and say, actually, this is the new normal and some things are not possible anymore. Thilo Yeah, it might be! I think we're not going to stop at off-white as a colour. But I would hope that for example new technologies in dyeing would produce perhaps a new set of colours, which I actually find very interesting. So, my goal, my hope is not at all to say, that in five years from now, we're going to live in a world of beiges and greys and browns, because this is what recycling is going to give us. But what I would hope for is that can reproduce the colours that were there, but in a new way. That we actually find new ways of applying colour, even new sets of colours through the technologies that we're going to develop. Chris Because you've got to keep a sense of, not optimism, but a sense of desire, right? I mean, you don't want to make everything beige. Thilo No, clearly that wouldn't work from a consumer's point of view. And at the same time, I think it's okay to question sometimes consumer behaviour. The subscription model is a great example. Like in Switzerland, if I'm not mistaken, the shoe is 30 Swiss francs a month, which is 360 Swiss francs a year, and the calculation behind that is that every half-serious runner uses at least two pairs of shoes a year. And so what you think at first is like a 30 bucks a month, that's quite something. But then if you buy two pairs of medium-to-high priced running shoes, that both will last like 600km, 800km, it's notably cheaper plus with the advantage that you can return them whenever, no question asked, and you know that they're going to end up in a reasonable recycling process. Copyright: ON Chris That’s very ambitious to make a shoe that is recyclable using environmentally-focused materials as a starting point. And you have to target that to serious runners. I mean there are people who perceive that sustainable materials have less performance behind them. Thilo I think to be honest, it's more than perception. We have to deal with a lot of materials, which are losing some of the performance once you recycle them. Because right now, the purity of the material that gets recycled is just not staying the same. Especially in a market where we speak about absolute high-performance athlete products with all kinds of performance indicators. Of course, this is a big challenge. If you look at the current set of, let's say, acknowledged super forms in the running industry, they're quite intense when it comes to production efficiency. I think they're not worse or better to recycle, but what's needed to produce them is quite a thing. The reality is we are in constant movement. On one the hand we have stuff that's been there for very long time, making steps and getting improved. But on the other hand, we're making new innovations. Sometimes the innovation is about weight or the innovation is about rebound and doesn’t initially focus on sustainability. So, what happens when we find something which has crazy performance but is just average in regards to sustainability? The question is, how do you deal with it? Chris And how do you deal with it? Thilo What you want is absolute high performance. And if then the overall sustainability metric looks a little worse than in what you want to use in the big production runs, I think it’s fine. Copyright: ON Chris Consumers are obviously responding very well. I see your shoes everywhere. I mean everywhere! So, let's talk about the CleanCloud a shoe that uses carbon captured from steel mills that has been converted into ethylene, which I saw in 2022, at K, which is another massive kind of innovation. Is that something that's still continuing? Thilo I think we have become a bit of a catalyst of ideas, some of which we push. Undeniably, the industry is like a partner, directly or indirectly. We all know that chemicals are part of the game. But I think what's needed is partners on the one hand that really push the ideation side and give a face to what innovation can look like. It's super important to visualise ideas because then it's easier to push things a little bit further. Of course, the right partners are needed on the side of the producing industries that then execute the idea Chris We're coming to the end of our interview. On is very bold and very assertive in the way that you talk about sustainability - you even publish your suppliers. It's very easy to be shot down by making any sustainability claims whatsoever and some companies don't, they just keep it very quiet. But you're very bold, you're full-throttle about doing that. Copyright: ON Thilo It's very valuable to be transparent. Because if you're in the industry, people know that it needs many pairs of hands to make a shoe. So, to communicate who we do that with, that's a big part of what we want to be. For me, transparency is the most important thing. In terms of design ambitions, I think you have to dream a bit, then to make it real. For me personally, it's always a very nice idea to dream up things as a benchmark to see if we can reach them. I think we need those dreams to hope after. Chris The last question is one I have asked many people, it is a very revealing question about our connections with materials on an emotional level and it is nice way to end the interview. What is your strongest material memory from childhood? Thilo I would guess it's the handle of a Swiss Army knife. Because it's one of the first childhood objects that I remember from playing outside, which of course, as a kid in the very first years you don't have any material dreams and this is probably one of the first things, perhaps, that you own and that you keep longer than two months. [Laughs] And then secondly, I really can remember the haptics right because it's always like this pebble that you have in your pocket that ages actually quite nicely. Chris Wonderful! It’s fantastic talking to you, thank you. Author: Chris Lefteri | K-Mag Chris Lefteri is a materials expert, author and industrial designer. Since 2006, he has been advising companies worldwide at the interface of materials innovation, CMF and design strategy. His books and lectures shape the global discourse on the conscious use of materials in design and industry. In K-Mag, he writes about the role of materials as drivers of sustainable product innovation. More around Materials Design

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  • Plastics in the Packaging Industry: More than just a protective cover

    Part 1 of the series “Focus on User Industries: Packaging” Exclusively for K-Mag Transparent or printed, small or large. There is the right packaging for every product. The variety of options on offer can be experienced again this year at K; Copyright: Messe Düsseldorf/ctillmann 06.08.2025 A cup that keeps yogurt fresh. A blister pack that protects medication. A tray that transports food. Plastic packaging is everywhere. And the choice of material determines durability, recyclability, and carbon footprint. While a PET yogurt cup guarantees freshness for weeks and is significantly lighter than glass, hygienic polypropylene in blister packs ensures sterile storage of medicines. Modern monomaterial packaging is much easier to recycle than composite materials, which often end up in residual waste. The carbon footprint of plastic packaging is often lower than that of alternative materials during transport due to its lower weight. This is clearly illustrated by rPET wine bottles, as explained in this interview with ALPLA ! But what exactly is “typical packaging,” and what criteria must manufacturers consider when selecting it? The answer lies in a complex interplay of material properties, application requirements, and sustainability goals—from the barrier function against oxygen to recyclability in the circular economy system. This means that there is no such thing as a one-size-fits-all packaging solution. It always depends on the specific product that needs to be packaged. Diverse applications of plastic packaging The packaging for products can be selected and designed as required; Copyright: Messe Düsseldorf/ctillmann Food packaging for greater hygiene and safety Plastics are indispensable in the food packaging industry. For example, PET dominates beverage bottles due to its barrier effect against CO₂, while polypropylene (PP) dominates yogurt cups due to its heat resistance up to 130°C, which is particularly hygienic when in contact with food. Polyethylene (PE) is used as LDPE for flexible cling film and as HDPE for sturdy milk bottles. Composite materials with barrier layers are used for more demanding applications. Packaging is essential for keeping medicines sterile. Medical packaging for greater patient safety Sterile and secure packaging is essential in the medical sector. PVC dominates blister packaging—it offers transparency for visual inspection if desired, and its low water vapor permeability protects medications from moisture. PE and PP withstand sterilization processes without damage, while cyclo-olefin copolymers (COC) offer glass-like transparency in injection vials with pharmaceutical purity. There are a multitude of design options for cosmetics packaging; Copyright: Messe Düsseldorf/ctillmann Consumer goods packaging for appealing products Plastic packaging offers numerous design options in the consumer goods sector. ABS enables high-quality visual appearances for cosmetics packaging with excellent surface quality, while PETG scores points in display packaging with its crystal-clear transparency. Boomerang packaging can be returned to the company via the mailbox; Copyright: boomerang Transport packaging to protect goods Robust yet lightweight packaging materials are required for the safe transport of goods. Various plastic solutions are used for this purpose: shrink and stretch films effectively secure pallet loads, while bubble wrap provides optimum protection for goods that are sensitive to impact. Expanded polystyrene, better known as Styrofoam, serves as reliable protective packaging due to its excellent cushioning properties. Plastic crates and containers have established themselves for reusable applications, impressing with their durability and stability while also protecting the environment through repeated use. Boomerang is a start-up that has impressed with an exciting idea for mail order. Its solution focuses on shipping bags made from recycled plastic as a sustainable alternative to disposable shipping bags. The bags help to reduce packaging waste by being reusable up to 50 times. They are made from 100% recycled polypropylene, are resealable, and can be stored and transported in a space-saving manner. Customers who order via the system can simply fold the shipping bag after delivery and return it to the company by mail. There, the bags are cleaned and returned to the cycle. A similar reusable system for parcel logistics has also been developed by BOOXit. Exciting insights into this system can be found in this K-Mag interview ! The most common plastics Polyethylene (PE): For films, bags, and bottles. Flexible, chemical-resistant, easy to weld. Polypropylene (PP): Stable, heat-resistant, and therefore ideal for cups, for example. Polyethylene terephthalate (PET): Resistant to many chemicals, therefore often used in food packaging such as bottles and trays. Polystyrene (PS): Known to many as Styrofoam. Lightweight and insulating, used for example in thermal packaging. Lighter and more resource-efficient Compared to other packaging materials such as glass or metal, plastics are significantly lighter. This leads to considerable savings in transport costs and is beneficial for climate protection: Lower fuel consumption and CO₂ emissions during transport Higher transport capacity per vehicle Less material consumption with the same protective function Recyclable packaging concepts Design for recycling is becoming increasingly important in packaging development. Solutions such as monomaterials are preferred over composites that are difficult to separate, and the use of recycled materials in new packaging is on the rise. In addition, color coding facilitates sorting in the recycling process, while problematic additives are reduced to improve reusability. Read our article on “Design4Recycling for yogurt cups” Recyclates have great potential When it comes to a closed material cycle, there is no getting around recyclates . Mechanical recycling is now well established, while chemical recycling is still in development. So, the approaches are there, but manufacturers are currently still faced with a price issue. New materials are often still cheaper than recyclates. Material savings through intelligent design Innovative designs and a sophisticated approach to material design significantly minimize the use of materials in modern packaging solutions. This not only leads to cost savings, but also contributes significantly to the conservation of resources: Thin-walled packaging with optimized stability thanks to special reinforcement ribs and strategically positioned stiffening elements that maintain mechanical strength despite reduced material usage Corrugated profile structures for greater rigidity with lower raw material consumption, transferring the biomechanical principle of natural structures such as corrugated cardboard to plastics Concentrates and multi-packs and refill packs with reduced packaging volume, which can reduce the material requirements for primary packaging by up to 80% while increasing transport efficiency Bioplastics in comparison: opportunities and limitations There are high hopes that bio-based materials will be able to replace fossil raw materials. These materials are based on sugar cane, corn, or cellulose, for example. Unfortunately, however, bio-based does not automatically mean environmentally friendly. Even bioplastics are not always biodegradable. Furthermore, they often end up in the same waste stream as conventional plastics. This means that their true potential is unfortunately wasted. However, the industry is continuing to work on finding solutions. Further information on bio-based plastics in food packaging can be found here! For anyone working on material innovation and future trends, packaging remains an exciting—and challenging—topic. Some of these new developments can be experienced at K 2025. What new applications will there be? If you don't want to wait until K 2025 in October, we will soon be presenting specific solutions from exhibitors in part 2 of our series “Focus on user industries: Packaging.” The portrait was generated by AI. Author: Simone Ernst | K-Mag Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry. At a glance Plastic packaging ensures freshness, hygiene, and product protection. Its low weight saves CO₂ during transport, while trends such as monomaterials, the use of recycled materials, and intelligent design improve recyclability and resource efficiency. Bio-based plastics are also becoming more prominent. More around Plastics in Practice

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  • Plastics in the Automotive Industry: All-rounders for Tomorrow's Mobility

    Part 1 of the series 'Focus on User Industries: Automotive' Exclusively for K-Mag Plastics have become an indispensable part of vehicle construction. They enable lightweight construction, design freedom, functionality and recyclability all at the same time. Copyright: Artinun – stock.adobe.com 09.07.2025 What do bumpers, door panels and cable sheathing have in common? They are often made of plastic – and for good reason. In the automotive industry , this material has long been more than just a substitute for metal or glass. Plastics save weight, protect components, enable complex shapes and open up new design possibilities. In part 1 of our series, we show where and how plastics are used in cars – and what they do there. Part 2 highlights how exhibitors at K 2025 are picking up on these developments and taking them further. Every modern vehicle now contains several hundred kilograms of plastic. This makes the automotive industry one of the most important customer industries for plastics processing. At the same time, innovations in plastics technology are shaping the transformation of mobility. Whether it's electric cars, lightweight construction or smart interiors: without plastics, little would be possible. Where Plastics are Used in Cars Plastics are not only everywhere in cars – they also perform a wide variety of tasks. Some are visible, others work behind the scenes. And often they have to do more than you might think at first glance. In the interior, plastics ensure comfort, ergonomics and individual design. Copyright: RomanR – stock.adobe.com Plastics in the interior: Dashboards, centre consoles, door panels Seat shells, trim parts, air vents Surfaces with haptic quality and functionality The design possibilities are enormous: plastics can be textured, coloured, foamed or combined with other materials. They contribute to brand identity and increase ease of use. Plastic exterior components are not only efficient to manufacture, but also easy to repair or replace. Eвгений Bершинин – stock.adobe.com Plastics in the exterior: Bumpers, mirror housings, lighting components Wheel arches, underbody panels Increasingly also structurally relevant parts made of fibre-reinforced plastic These components must be lightweight, robust and weather-resistant. Many of them are made of thermoplastic polymers, which are easy to process and recycle. Technical plastic components provide protection, insulation and temperature resistance. Copyright: sarymsakov.com – stock.adobe.com Plastics in technical components: Cable sheathing and connectors Housings for sensors and control units Fuel lines, containers, tanks Plastics insulate, seal and withstand high temperatures. In high-voltage electrical systems in electric vehicles, they provide reliable protection against overvoltage and short circuits. The areas of application show that plastics are not just an accessory. They are a central element in vehicle construction – functional, lightweight and versatile. Innovation and Efficiency: Why Plastics are Used in Cars The demands placed on vehicles are increasing. They are expected to be more efficient, lighter, quieter, safer and more sustainable – ideally all at the same time. Plastics make a decisive contribution to this. Today, they are a driver of innovation for the automotive industry. Lightweight construction is the key word here. Plastics such as polyamides , polycarbonates and fibre-reinforced thermoplastics help to reduce weight – and thus save energy. Less mass means lower consumption, whether in combustion engines or electric cars. Every kilo saved counts, especially in battery and hybrid vehicles. The transition to electric mobility in particular is opening up new areas of application. High-voltage cables, battery housings, sensor components – all of these require high-performance plastics. Plastics are also playing an increasingly important role in acoustics and vibration damping. They ensure a smoother ride – and make the difference audible, especially in quiet electric vehicles. Plastics and design go hand in hand. Copyright: Messe Düsseldorf Plastics also score points in terms of design and function: They allow complex shapes to be produced in one piece. They enable multiple functions to be integrated into a single component. They offer scope for new interior design concepts. Sustainability and Regulation: ELV Directive as a Game Changer? The EU End-of-Life Vehicles Directive sets new targets for the use of recycled materials and ease of dismantling. Copyright: Plastics Europe Plastics in cars not only have to be technically convincing – they are also increasingly coming under regulatory pressure. The new Directive on end-of-life vehicles (ELV Directive) is bringing change. Its goal: more recycling, longer usability, less resource consumption. The ELV Directive was politically agreed upon by the EU Environment Council on 17 June 2025 . It is currently still in the legislative process – an agreement with the European Parliament and the EU Commission is expected by the end of 2025 . Once the ELV Directive has been adopted, there will be a transition period of five years . The new requirements would therefore become mandatory from around 2030 . However, it is already clear today that the directive will bring about significant changes in the design, production and recycling of vehicles, particularly with regard to the use of plastics. Key points of the ELV Directive: 25% of plastics in new vehicles must come from post-consumer recyclates . Vehicle components such as bumpers, cable harnesses and tanks must be easier to dismantle and recycle. Digital recycling passports and standardised recycling certificates are intended to ensure greater transparency. For the plastics industry, this means it must deliver solutions – in material development, design for recycling and processing methods. Mechanical recycling alone is not the only way forward. Chemical and solvent-based recycling , the use of bio-based raw materials and CO₂ as a carbon source are also coming into focus. The challenges are considerable: Consistently high-quality recyclates Cost and supply security Recognition of new recycling processes in regulations … but so are the opportunities: Development of new markets for secondary raw materials Partnerships along the value chain Development of circular business models The regulation could thus become a lever – not only for more sustainable vehicle production, but also for a more robust plastics industry in Europe. Did you know? Modern cars consist of around 15-20% plastic – often equivalent to more than 300 kg per vehicle. 1 kg of plastic replaces up to 2 kg of metal. This saves around 0.5 litres of fuel per 100 kilometres. Some plastic parts in cars already consist of up to 100% recycled material, e.g. in underbody panels. Outlook: Plastics Expertise Meets Mobility Needs At K, exhibitors show how plastics are contributing to the transformation of mobility – from new materials to circular production solutions. Copyright: Messe Düsseldorf Plastics have become indispensable in the automotive industry. Their low weight, high strength and design flexibility make them the ideal material for a wide range of requirements. And less weight means lower energy consumption – and thus lower CO₂ emissions when driving. As their importance grows, so do the requirements – technical, economic and regulatory. But the industry is responding. It is developing new materials, recycling solutions and concepts for the circular economy . Much of this is being done in collaboration with OEMs, suppliers and research institutions. This dynamic is also evident at K. Here, companies from across the value chain are presenting what plastics can achieve in vehicle construction today and tomorrow. Part 2 of this series takes a closer look at exactly that: What solutions are exhibitors presenting for the mobility of the future? Which materials, technologies and processes are the focus? And how are suppliers from the plastics industry using K 2025 to position themselves as partners to the automotive industry? Click here for part 2 of the series! One thing is clear: The mobility transition needs plastics – and K is the place where it becomes clear how this connection can be achieved. The portrait was generated by AI. Author: Elena Blume | K-Mag Elena Blume has been writing for various industry magazines for eight years and joined the K-Mag editorial team in 2021. She is particularly interested in topics related to innovative plastics solutions that contribute to sustainability and address current challenges relevant to industry and society. At a glance Plastics have become indispensable in vehicle construction: they enable lightweight construction, flexible designs and innovative technology. New EU regulations such as the ELV Directive require greater use of recycled materials and recyclability – thereby driving innovation in the plastics industry. More around Mobility

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  • Plastic Batteries in the Focus of Research

    Energy storage without Lithium Exclusively for K-Mag We can still speculate about what batteries will look like in the future. What is certain is that new models are coming; Copyright: Drapix - stock.adobe.com - AI generated 21.05.2025 The demand for sustainable energy storage systems is growing. However, many conventional batteries rely on critical raw materials such as lithium. Prof Birgit Esser is researching an exciting alternative at the University of Ulm: plastic batteries. In an interview with K-Mag, she talks about the advantages of polymer batteries, how they work and their potential for everyday applications. Her goal: to rethink energy storage: environmentally friendly, flexible and economical. Prof Esser, you are researching polymer-based batteries without lithium and rare metals. What fascinates you personally about this approach? Birgit Esser : I am fascinated by the fact that we can utilise the diverse chemistry and modulable properties of organic compounds to store energy. Organic chemistry provides us with a construction kit from which we can equip molecules and materials with the desired properties and assemble them in different combinations as electrode materials in battery cells . How plastic batteries differ from lithium-ion systems Birgit Esser; Copyright: private How do plastic batteries differ fundamentally from conventional lithium-ion systems in terms of structure and function? Esser: Lithium-ion batteries have two electrode materials that alternately absorb lithium ions from the electrolyte along with the electrons. The lithium ions move back and forth between the positive and negative electrodes between charging and discharging, which is where the battery gets its name. There are various possibilities for batteries in which a plastic replaces one or both of the electrode materials: After absorbing electrons, the plastic can also absorb a metal ion (e.g. a lithium ion) from the electrolyte, in which case it would be a so-called n-type material. Or the plastic can release an electron (thereby being oxidised) and absorb an anion from the electrolyte to compensate for the charge. This would be the case with a p-type material. This second class of material is very common in organic electrode materials but is rarely found in inorganic materials. One example from inorganic materials is graphite. In the development of a battery cell, both p-type and n-type organic electrode materials in the form of plastics can now be used in principle to obtain different configurations with regard to the movement of the ions in the battery. With plastics as electrode materials, it is also possible to replace the lithium ions with other metal ions that have a more favourable geographical availability. Here we are working intensively on multivalent metal batteries based on aluminium or magnesium instead of lithium, among other things in the POLiS Cluster of Excellence at the University of Ulm . What criteria must polymer materials fulfil in order to be suitable for batteries? Esser: The most important criterion is redox activity , i.e., the material must be able to reversibly accept (n-type material) or release (p-type material) electrons. This requires redox-active groups in the material, e.g., conjugated quinones or aromatic heterocycles. Some of these are units that also occur in many natural substances. A second important criterion is that the material is insoluble in the battery's liquid electrolyte. Battery electrolytes are very polar solvents that must dissolve the conductive salt (e.g., a lithium salt) required in the battery. However, they must not dissolve the organic electrode material, otherwise the battery would short-circuit. For this reason, the redox-active groups mentioned above are incorporated into a polymer, which is often also cross-linked. This results in a linked network of the redox polymer, which remains immobilised in the electrode. This type of cross-linking is also used in conventional plastics. Other criteria are a redox potential that leads to an attractive cell voltage depending on the configuration of the battery. The desired cell voltage depends on the application of the battery. Organic electrode materials with a high redox potential are often desirable if, for example, a metal electrode is used as the opposite pole. How do you manage to specifically adapt the properties of plastics? Esser: Organic synthesis chemistry offers a wide range of possibilities here. Once a redox-active group has been identified that can be reversibly reduced or oxidised, the redox potential can be adjusted by chemical modification, e.g., the addition of substituents. This group can also be incorporated into a polymer structure by chemical modification in order to achieve insolubility in the battery electrolyte. Sometimes it is also the case that decomposition processes of the electrode material during its use in the battery are analysed in detail and provide information about sensitive positions in the organic molecular structure. These positions can then be modified by changing the molecular structure, and this can lead to a more stable, cyclisable electrode material. Where do you currently see the biggest areas of application for plastic batteries? Esser: On the one hand, there is the area of stationary energy storage , where a large increase in demand is expected in the coming decades. The criteria here include low costs, no toxicity, high safety, and longevity, and I see a lot of potential for organic electrode materials, e.g. also in combination with ‘post-lithium’ metals. On the other hand, plastics offer unique properties in terms of their processability and mechanical flexibility. They are therefore also excellent candidates for thin, bendable and printable batteries for applications with low-capacity requirements but strict specifications for the cell design of the battery. Exhibitors & products around plastics processing Processing technologies Follow on treatment of plastics products Supplying Product groups Products To all exhibitors in this category Recycling benefits by dispensing with critical raw materials What challenges do batteries pose when it comes to recycling? Esser: When it comes to recycling, separating valuable components from a battery is very complicated and cost-intensive. If plastic-based batteries therefore do not contain any valuable components, this should also simplify their recycling. Where do you see the plastic battery possibly being in five to ten years' time? Esser: The development of new battery technologies is a lengthy process. It has also taken decades for the lithium-ion battery from the identification of suitable electrode materials to their commercialisation and large-scale application. I assume that in five to ten years we will have made great progress in identifying organic plastics that are potential candidates for alternative batteries, including so-called post-lithium cell chemistries. This will follow from the intensive study of the design of organic electrode materials, and their energy storage processes in different battery types, and the targeted development of improved materials. What motivates you most in your research into sustainable energy storage? Esser: I am motivated by the fact that I can make a contribution to tackling our society's major challenge of ‘clean energy’. I am also motivated by supporting students and young scientists in an important phase of their careers and thus having a lasting influence on research and science. You can find out more about batteries in the K exhibitor database here! Simone Ernst (K-Mag editorial team) More about plastics in everyday life

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