Products: Good Product Design
A deep dive into what makes the difference between a good and bad product made from recycled plastic.
Introduction
Making the right choice on the products you select is one of the key decisions you will need to make when starting a project with recycled plastic. A well-thought-out product choice not only improves your chances of creating a viable and successful business model but also makes the entire fabrication process smoother and more enjoyable. The difference between good and bad product design often comes down to how you leverage the materials available and how thoughtfully you approach the design process. In this blog post, we’ll dive deep into what separates good product design from bad when working with recycled plastics. From selecting the right material to adding value with innovative functionality, these insights will help you make informed decisions and ultimately build better products.
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Small Items Create Big Value
When designing with recycled plastic, many people are tempted to make large items to use up more material. However, bigger isn’t always better. Large products may seem impactful, but smaller items can often generate more value per gram of plastic, which is technically upcycling! Creating smaller, high-quality objects allows for more efficient use of recycled material and often leads to products that are easier to manufacture and sell. Small, well-crafted items can provide a higher return on material investment, reducing waste while still creating something valuable.
(Photo Credits: Behaviour Change Cornwall)
Avoid Overly Thick Designs
Following on from the size, another common misconception is that thicker products will help recycle more plastic, but this approach often backfires. Thick items are not only expensive to produce due to the cost of preparing and cleaning the plastic, but they also present technical challenges. Plastics shrink when they cool, and overly thick designs can cause defects like sink marks, impacting the quality of the final product. A thickness of 6mm should generally be the upper limit for most designs to ensure efficiency, reduce material costs, and maintain high-quality standards.
1mm is about the thinnest we would recommend but this depends on the plastic type and overall design.
Match Your Design to the Plastic’s Properties
Not all plastics are created equal, and a common mistake is assuming any type of recycled plastic can be turned into any product. The key to good product design lies in understanding the properties of the plastic you have available and designing around its strengths and limitations. Alternatively, if you have a specific product in mind, choose the plastic type that best suits its functional requirements. Whether it’s the flexibility of LDPE or the durability of HDPE, let the material’s characteristics inform the design for the best results.
Design for Injection Moulding, Not 3D Printing
A common mistake in sustainable design is attempting to directly copy a product made for 3D printing and expecting it to work for injection moulding. The two processes are fundamentally different, each with its own set of design requirements. 3D printing accommodates limited overhangs and complex internal structures that can be impossible or inefficient to reproduce with injection moulding. When designing for injection, think about factors like parting lines, draft angles, and avoiding undercuts. By embracing these design principles, you can ensure that your product is optimized for the injection moulding process, making it easier and more cost-effective to manufacture.
What is our favourite type of plastic? It is PP (Polypropylene)
A High-Quality Mould for a High-Quality Product
One of the most critical factors in ensuring a high-quality product is the quality of the mould itself. A well-designed and precisely manufactured mould can minimize or eliminate the need for post-processing, such as sanding or cleaning up excess material. The fewer steps needed after moulding, the more efficient and consistent your production process will be. Investing in a high-quality mould not only saves time but also improves the final product's appearance and durability. Skimping on mould quality often leads to costly delays and unsatisfactory outcomes, so this is an area where attention to detail really pays off.
Embrace Your Price Point and Unique Texture
One reality of producing products from recycled plastic is that they are unlikely to be cheaper than mass-produced items. Instead of competing solely on price, embrace the unique value of your sustainably made product. Consumers today are eager to support grassroots, eco-friendly brands. What sets your design apart is not only its environmental impact but also its distinct polymarbling texture—a beautiful and one-of-a-kind feature that results from using recycled materials in the injection process. This natural marbling effect is something that can’t be replicated in mass production, making your product truly unique. Highlight this as a selling point, and lean into the appeal of sustainable craftsmanship.
Design For Future Recycling
When creating products from recycled plastic, it’s essential to also consider their end-of-life cycle. Designing for future recyclability means making it easier for your product to be recycled again once it has reached the end of its use. Where possible, incorporate recycling symbols and numbers directly onto the product to clearly indicate the type of plastic used. This helps consumers and recyclers identify the material and process it appropriately. By doing this, you’re contributing to the circular economy and ensuring that your product doesn’t end up as waste.
Highlight Sustainability with Logos and Messaging
Another important aspect of sustainable design is making sure that the product itself tells the story of its eco-friendly origins. Consider embedding logos, messages, or symbols directly into the mould to highlight its sustainable nature. Whether it’s a simple recycling symbol or a unique logo that communicates your commitment to sustainability, this branding not only educates consumers but also increases the perceived value of the product. By showcasing the sustainability of your product right on its surface, you’re ensuring that everyone who uses or sees it understands its eco-friendly impact.
Thoughtful Packaging Completes the Product
Packaging is an often-overlooked aspect of product design, but it plays a crucial role in reinforcing your brand's sustainability values. Since your product is made from recycled plastic, your packaging should reflect that commitment. Consider using recycled materials for packaging, minimizing unnecessary waste, and opting for eco-friendly printing techniques. Not only should the packaging protect your product during shipping, but it should also tell the story of your sustainability mission. Simple, reusable, or recyclable packaging can make a big difference in how your product is perceived, and it further aligns with the eco-conscious values your customers are seeking.
(Photo Credits: Brothers Make)
That Was A Lot Of Information!
Designing products from recycled plastic is both an exciting opportunity and a complex challenge. From choosing the right materials and designing for specific processes, to maximizing functionality and embracing sustainability, there’s a lot to consider when turning waste into something valuable. By following the principles outlined here, you can create products that not only stand out but also contribute to a greener future.
If you're feeling inspired but unsure where to start, we are here to help. At Sustainable Design Studio, we specialise in bringing your ideas to life with thoughtful, efficient, and eco-friendly designs. Whether you’re looking to create a small, high-value item or need guidance on material selection and mould design, we have the expertise to make your vision a reality. Get in touch with us today, and let’s work together to design products that make a difference.
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