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Why is Injection Moulding the Gamechanger for Sustainable Manufacturing?
If you look around you, chances are that you can see, touch, or use many objects that have been produced using injection moulding. This manufacturing process entails melting plastic granules and injecting them into a mould cavity to create a three-dimensional part that can be replicated quickly and precisely. Injection moulding has enabled the mass production of diverse and complex items, such as car parts, toys, packaging, medical devices, and electronic components, to name a few. However, injection moulding is not just a reliable and efficient technology for making high-quality products; it is also becoming a gamechanger for sustainable manufacturing in several ways.
First, injection moulding can reduce waste and energy consumption compared to other methods of production. Because injection moulding only uses the exact amount of material needed to fill the mould, it generates little or no scrap, which is not the case with subtractive processes like milling or cutting that generate waste streams. Moreover, injection moulding can use recycled or biodegradable materials instead of synthetic plastics, which can decrease the carbon footprint and dependency on fossil fuels. For instance, a company called Bockatech uses an additive called EcoCore to produce bike helmets that are recyclable, low in density, and high in impact absorption. Another company called Evolve Additive Solutions has developed a 3D printing process called STEP that uses recyclable thermoplastics and eliminates the need for support structures, reducing material consumption and post-processing time.
Second, injection moulding can foster design innovation and customisation by enabling complex geometries and features that would be hard or impossible to create with traditional manufacturing methods. Complex geometries can reduce weight, increase strength, and improve functionality, leading to more efficient and durable products. Customisation can enable personalisation, localisation, and on-demand production, reducing inventory, transportation, and overproduction. For example, a company called Felix Printers uses injection moulding to create customised parts for its 3D printers to improve their stability and usability. A company called Custom Plastics International uses injection moulding to create customised parts for various industries, such as agriculture, automotive, and medical, using 3D printing, computer-aided design, and rapid prototyping.
Third, injection moulding can support circular economy principles by enabling the recovery and reuse of materials, products, and parts. Injection moulding can help close the loop of the plastic life cycle by enabling the creation of recyclable or biodegradable products that can be collected, sorted, and transformed into new feedstock or other applications. Injection moulding can also enable the repair, remanufacturing, or upgrading of products and parts, extending their lifespan and reducing waste. For example, a company called Terracycle offers a service called Re-TerraCycle that collects and recycles hard-to-recycle plastics, turning them into new materials or products. A company called Precious Plastic offers a set of open-source machines and tools for recycling plastic waste and creating new products, including an injection moulding machine that can be operated locally.
Fourth, injection moulding can enhance safety and health by reducing or eliminating hazardous chemicals, emissions, or waste streams that can harm the environment or human health. Injection moulding can use materials that are free from toxic additives or pollutants, such as polypropylene or polyethylene, which are considered safer than polycarbonate or PVC. Injection moulding can also use technologies that capture or treat emissions or waste streams, such as gas scrubbers or closed-loop systems, that prevent exposure or contamination. For example, a company called Green Rubber Global uses a patented process called DeLink that uses supercritical carbon dioxide to devulcanise rubber waste, making it recyclable and safer to handle. A company called Dell uses closed-loop recycling to recover plastics from its discarded products and reuse them in new ones.
In conclusion, injection moulding is a versatile and valuable technology that can contribute to sustainable manufacturing by reducing waste and energy consumption, fostering design innovation and customisation, supporting circular economy principles, and enhancing safety and health. However, injection moulding is not a panacea or a magic bullet for all sustainability challenges, as it still relies on fossil fuels, generates emissions and waste, and faces limitations in terms of material choice, scalability, and compatibility with other processes. Therefore, injection moulding should be part of a broader and multidisciplinary approach to sustainability that considers the entire life cycle of the product, the ecosystem, and the social and ethical dimensions of production and consumption. Through collaboration, innovation, and leadership, different stakeholders can leverage the potential of injection moulding and other technologies to create a more sustainable and equitable future for all.
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