As we have seen, applying recycled plastics in a new product requires a different design approach because their characteristics are different from those of virgin plastics. Often the exact mechanical or aesthetic properties of the material, or how it will perform during production, are unknown. The challenge for designers and engineers is to fill in these information gaps and reduce the uncertainties concerning the recycled material. In the following video, Thijs Feenstra, circular product design lead at the product development agency Pezy Group, introduces the ‘drop in method’, a tool that can be used to navigate these uncertainties.

Main Takeaways

• The ‘drop in method’ is a step-by-step process to learn about, and then apply, recycled plastic grades. It consists of three pillars.
• The complexity level tool helps to analyse which of your product’s parts are the easiest to manufacture with recycled plastics.
• The six steps to material approval pillar helps to gradually build confidence in the application of recycled grades into your product.
• The look and learn pillar is about creating samples, or demonstrators, to learn about the aesthetic and mechanical properties and remove uncertainties about the recycled material’s behaviour. Start with existing moulds so you can compare parts made from recycled and virgin plastics.
• Once the knowledge gap about the material is filled it becomes possible to design entirely new products with it.