Building in multifunctionality in plastic components : complexity, cost and sustainability

Abstract

Multifunctionality can be embedded into material systems by three distinct design processes. These are: firstly multifunction can be embedded at a material level such as the use of nanomaterials within a polymer. In the second instance, discrete material systems can be added together. Examples are laminate systems in food pouches consisting of thin layers of metal and polymer. In the third process this can be achieved by integrating these materials systems together to form one holistically behaving component with multifunctionality. An example is an embedded antenna in an automotive windscreen.Drivers for multifunctionality include the increased push towards intelligent objects, such as the creation of the internet of things. Here, the embedding of communication and electronic function into daily consumer objects, such as milk cartons and food packaging are demanded. This must be offset by consideration of the related rise of a new wave of short-lifetime waste electronic and electronic equipment, incapable with current plastic recycling infrastructure, for disposal systems to adapt too. Designing integrated and multifunctional plastic components however, is complicated by the sheer number of material choices, multiple processing platforms, cost implications and environmental legislation. Considering just the processes of injection moulding, compression moulding and additive manufacturing, a designer is confronted with considerable complexity and numerous engineering design and stakeholder issues to consider. This paper presents examples of current state of art in multifunctional systems and discusses the barriers and potential solutions to creating fully realized multifunctional systems within a polymeric manufacturing environment. Impacts on material lifecycles and disposal infrastructures must be considered, as is the necessity to retain diversity with new integrated and advanced manufacturing processes suitable for the demands of mass customization, automation and Industry 4.0.