Apple HomePod Mini featuring a seamless knitted spacer textile speaker cover and injection moulded transparent plastic touch panel. In the development of the HomePod, a tubular spacer textile construction was developed to remove the need for an unsightly seam. Spacer textile is a highly breathable warp-knitted fabric consisting of two faces connected with filaments in the middle. The mesh acts as both an acoustically transparent cover for the speaker and cushion to protect the electronics within.
In this ultra-thin product cover demonstrator, a Tepex woven carbon fibre reinforced thermoplastic polyurethane (TPU) sheet is formed and over-moulded with polycarbonate (PC-GF50), and decorated with a Kurz in-mould lamination (IML) film, in a single process on an Engel press.
In this ultra-thin product cover demonstrator, a Tepex woven carbon fibre reinforced thermoplastic polyurethane (TPU) sheet is formed and over-moulded with polycarbonate (PC-GF50), and decorated with a Kurz in-mould lamination (IML) film, in a single process on an Engel press.
Plntprtct phone cases by AGood Company are made with a mix of polylactic acid (PLA), polybutylene adipate terephthalate (PBAT) - two types of biodegradable polyester - hemp, flax and cellulose. The material is industrially compostable and recyclable. Image AGood Company.
A demonstrator by Kurz to show off their wood-effect polyester foil hot stamped onto acrylic sheet, which is backlit with integrated tough sensor. A black mask is printed on the reverse side of the semi-transparent foil, which helps control the lighting effect. This kind of technology is used in appliances as well as automotive applications. In car interior applications, where head impact is a risk, polycarbonate (PC) is preferred over acrylic (PMMA).
The front grille for the BMW iX is produced in a cleanroom environment, since any dust would be visible through the high-gloss polyurethane (PUR) finish. Produced in an integrated process, the component consists of a functional film that is back-injection moulded with polycarbonate (PC) and then flood-coated with 2-3 mm PUR. Engel developed the production cell.
Karcher pressure washer with injection moulded polypropylene copolymer (PPC) housing. This material is chosen for its very high impact properties, low density and low cost.
Injection moulded polypropylene (PP) with 30% lignin additive. The lignin is a by-product of paper making and forestry, and can be mixed directly with the to produce a bio-based composite.
Polyamide 6 (PA), nylon, from recycled scrap. The colour that can be achieved in recycled plastic depends on the source of waste. In this case, Kolon produce recycled PA from old ship mooring ropes, the core of which provides a relatively clean source of material suitable for bright colours. If mixed waste is used, light bright colours are not usually possible, unless sophisticated sorting is employed to separate white and clear from coloured, which increases cost.
A power tool housing injection moulded in 30% glass fibre reinforced polyamide 6 (PA-GF30). A combination of additives and surface texture help to conceal the visual impact of the fibres.
Some example colours in polybutylene succinate (PBS) by Sun Circle with masterbatch (colour) by Grafe. PBS provides a home compostable alternative to polypropylene (PP) and polyethylene (PE) in packaging applications, for example.
Black & Decker Reviva cordless screwdriver, the housing of which is made with Tritan Renew copolyester containing 50% post consumer recycled (PCR) plastic. The material is chemically recycled from single use polyester packaging and converted into an engineering material suitable for demanding applications. Image Black & Decker.
EVBox's new Livo electric vehicle charging wallbox is made with Makrolon RE polycarbonate (PC) from Covestro. Makrolon RE is produced proportionately from biowaste and residual materials, partly using renewable electricity, and therefore has a relatively lower carbon footprint. Image EVBox.
Thinksound ov21 over-ear headphones. The plastic parts are moulded from Eastman Treva, cellulose bioplastic, and the wood cover is walnut. According to Thinksound, the cellulose engineering bioplastic helps to reduce resonance, distortion, and improve acoustic performance. Image Thinksound.
Die casting in Zamak 5 by Matthies Druckguss (Germany). The three-piece bayonet XT-A is a heat sink for an LED light. Image Matthies Druckguss (Germany).
Lumisty is a film with a specially textured surface that changes the transparency depending on the angle of view. Based on biaxially oriented polyethylene terephthalate (BOPET) polyester film, this kind of view control film is used in architecture laminated to glass, interiors, lighting and consumer electronics (privacy film on computer screens).
The Nike+ Fuelband activity tracker, launched 2012, is encapsulated within a thermoplastic elastomer (TPE) skin. A flexible circuit board is mounted onto an injection moulded polypropylene (PP) chassis. The whole assembly (circuit board, processor, sensors, antenna, USB connector and LED lights), but excluding the batteries, is placed into a mould and injection over-moulded with a TPE skin in a two-stage process (inside then outside).
Mobile phone cover, featuring steel with two layers of colour produced by physical vapour deposition (PVD), which is laser etched to produce a graphic visual effect. Aluminium titanium nitride (AlTiN) provides the black, masking a layer of silver chromium nitride (CrN) below.
Gucci watch back plate, in stainless steel, chemical etched graphics, with titanium carbonitride (TiCN) coating for protection and to provide a very durable rose gold colour
Mobile phone cover, featuring steel with two layers of colour produced by physical vapour deposition (PVD), which is laser etched to produce a graphic visual effect. A top layer of zirconium carbonitride (ZrCN) provides the blue colour, and is selectively removed to reveal the gold coloured zirconium nitride (ZrN) layer below.
iPhone 4 bezel, forged from stainless steel, prior to CNC machining. Forging produces the strongest possible bezel, because the grain of the steel is optimised and the structure hardened.
TIPSiV injection moulded elastomer is a hybrid of thermoplastic polyurethane (TPU) and silicone produced by Dow Corning. It combines the benefits of TPU with the unique tactility and durability of silicone. It takes colour well and is resistant to fading.
Positive Plastics injection moulded sample of Borealis Borcycle recycled polypropylene (rPP). It is mechanical recycled using a process that ensures light colours are possible.
Injection moulded hubcaps that combine Oryzite (rice husk based bio-filler) and polypropylene (PP). It can be combined with many types of plastic. Using bio-filler reduces plastic consumption and can have some beneficial impacts on mechanical properties and price. However, it means the plastic is unlikely to be recycled end of life. As well as automotive, it is used in many applications already including packaging, product enclosures, pallets and household items. Image Oryzite.
Sample of Roctool compression moulded polypropylene reinforced with recycled nonwoven carbon fibre (PP-CF40) to show print-though of fibre texture using various engraved Mold-Tech surface finishes.
Terralene GF30 by FKuR is a partially bio-based polyethylene (HDPE) with 30% short glass fibre. It provides a drop-in replacement for fossil-based PE and is suitable for technical injection moulded parts. Image FKuR.
Samples of phone back covers using injection moulded PC/ABS with various material integrated by in-mould labelling (IML) and in-mould decoration (IMD). With IML, a film such as PC or PET is printed with colour and graphics, thermoformed and integrated into the injection moulding process by thermoforming and back-injection, locking the print layer between the film and plastic part - the film and moulded plastic form a permanent bond. With IMD, the decorative layer is supplied on a carrier film, which provides support during the moulding process and is removed afterwards, leaving behind the print, hardcoat, or other decoration. With these techniques, fabric, leather, suede, veneer, mirror film, print, haptics and other effects are integrated into the part during moulding, avoiding secondary processes (like printing and painting).
A handheld gas detection device, moulded in polycarbonate (PC) with a thermoplastic elastomer (TPE) overmoulding. Multishot injection moulding a soft material over the rigid housing creates the opportunity for a seamless finish, hermetic seal and colour.
Antenna technology demonstrator, manufactured from injection moulded polycarbonate, which has been laser direct structured (LDS) to allow for localised metal plating
Panasonic Toughbook cover, thixomoulded (similar to injection moulding) in magnesium AZ91. The same technique is used in the production of cameras, mobile phones, displays and televisions. The magnesium is painted to protect it from oxidisation when in use.
Schott Nextrema glass ceramic sheet. It is available in a range of colours, including transparent, translucent white, opaque white, tinted, translucent blue-grey and opaque grey. Due to its robustness at very high temperatures, thermal shock resistance and impermeability to gases, it is used in a range of demanding industrial as well as domestic applications, for things like heating a lighting (sauna, IR-heating), cooking appliances (toasters, grills, microwave), and cover panels (such as for heating elements). Image Schott.
Copenhagen International School, by C. F. Møller, completed 2017, features a facade of over 12,000 SolarLab solar panels (covering over 6,000 sqm). The satin finish tempered glass cladding is vacuum deposition coated with silicon nitride (SiN) to provide an anti-reflective surface, interesting colour and conceal the electronics behind, without affecting their efficiency. A range of metallic and ceramic colours is possible with vacuum deposition - each with different optical and functional properties.
Copenhagen International School, by C. F. Møller, completed 2017, features a facade of over 12,000 SolarLab solar panels (covering over 6,000 sqm). The satin finish tempered glass cladding is vacuum deposition coated with silicon nitride (SiN) to provide an anti-reflective surface, interesting colour and conceal the electronics behind, without affecting their efficiency. A range of metallic and ceramic colours is possible with vacuum deposition - each with different optical and functional properties.
Positive Plastics injection moulded sample of Symbio cellulose fibre reinforced polypropylene (PP). It is equally well suited as reinforcement in polylactic acid (PLA) and provides a lightweight and renewable alternative to glass fibre reinforcement, and stronger and stiffer alternative to talc. Applications for this type of bio-based composite span automotive, consumer products, electronics and furniture.
Positive Plastics injection moulded sample of Symbio cellulose fibre reinforced polylactic acid (PLA). It is equally well suited as reinforcement in polypropylene (PP) and provides a lightweight and renewable alternative to glass fibre reinforcement, and stronger and stiffer alternative to talc. Applications for this type of bio-based composite span automotive, consumer products, electronics and furniture.
Electronics housing produced from injection moulded polylactic acid (PLA) reinforced with 20% rayon fibre made by Cordenka. The addition of rayon fibre increases the glass transition temperature (heat resistance) enough to make it suitable for electronics housing.
Colour-tinted and frosted glass cover on the backside of the Apple iPhone 15, with aluminium alloy bezel. The glass is coloured throughout, to create a translucent effect and coated on the backside to mask the internals. The aluminium bezel is machined and injection over-moulded.
Bang & Olufsen BEOPLAY HX headphones feature lambskin leather ear cushions, with polyurethane foam padding and a gold-colour anodised aluminium frame, using the dip and dye method.
HTC Legend mobile phone housing, sculpted from a single piece of extruded aluminium. The profile is extruded sideways and then CNC machined to the final shape. Techniques have evolved to mass produce fully machined housings like this (same as Apple unibody products). All the scrap can be recycled directly.
Aluminium bezel for a consumer electronic product, showing the stages of forging (top) a near net shape, followed by CNC machining (bottom) precise features
Positive Plastics injection moulded samples of Green Isoter recycled acrylonitrile butadiene styrene (rABS). It contains around 50% recycled industrial scrap with an intentional speckled finish. It is suitable for products, electronics, household items, automotive and toys, for example.
Spot Material is a database of materials for sustainable design, curated by Rob Thompson. Compare properties, carbon and end of life, find better alternatives and discover new material innovations Check your material for free →
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