The examination of material and design has various starting points. On the one hand, ideas and concepts lead to the determination of a suitable material. On the other hand, the choice of material can also be the core of the design and thus influence the design from the outset. During the 2024 winter semester, students on the Industrial Design course worked intensively with thermoplastic residues (plastic waste) as part of the "Ripped-Up" project at the State Academy of Fine Arts (ABK) in Stuttgart. The aim was to identify potential for the sustainable design of future products and produce initial prototypes.
After first classifying and examining plastics that they had collected themselves in a workshop, the students were able to explore the different types and properties of plastics. They received theoretical and practical support from the mechanical engineering company WEIMA from nearby Ilsfeld, just outside Heilbronn. Knowledge about the topic of plastics recycling and its industrial process steps was imparted during a guest lecture.
Workshop presentation about recycling
WEIMA then provided a compact Precious Plastic single-shaft shredder from its own production, almost 60 kg of granulate and a hand-operated injection molding machine for experimentation in the ABK plastics workshop. It is planned that the equipment will also be available for future projects at the ABK.
WEIMA Shredder Pro in Stuttgart
The second step involved developing ideas for a product and combining these with the knowledge acquired. What are the special features of the respective plastics? Which type of thermoplastic can be used for a design in a statically and structurally sensible way?
Different approaches were pursued in the course. From the use of granulates in the injection molding machine to fusion in the thermoforming machine or the ironing of plastic bags, the students took an explorative approach to the further processing of the residual materials. The results also covered a broad spectrum: from lightweight bags, plates, pieces of furniture and jewelry to modular semi-finished products.
Plates made from recycled plastic
One challenge was the availability of the materials, the unpredictability of the material quality and the short time available for processing. In this context, however, the students learned to use adequate substitute materials or to define placeholders.
Furthermore, the importance of material separation for the further processing of residual materials has become clear, where a homogeneous, high-quality material was required for the design.
Overall, the students were able to explore the processing of recycled plastics experimentally and creatively. They also had the opportunity to see themselves as designers at an important interface in the reuse of materials.