Plastics : Product design in the plastic industry

Product design in the plastic industry is a multidisciplinary process that transforms concepts into manufacturable plastic products through strategic material selection, engineering principles, and manufacturing considerations. It balances technical requirements, aesthetic appeal, usability, and sustainability while leveraging plastic's unique properties of moldability, versatility, and cost-effectiveness.

Key aspects include:

Material selection and engineering

Chooses specific polymers based on performance requirements. 

Example : 

Nalgene revolutionized laboratory equipment with their virtually unbreakable polycarbonate bottles, which replaced fragile glass while providing transparency, chemical resistance, and autoclave compatibility, dramatically reducing lab breakage incidents.

Design for manufacturability

Optimizes products for efficient production. 

Example : 

Tupperware's famous "burping seal" required precise engineering with very specific wall thicknesses and living hinges that flex millions of times without breaking, while allowing efficient high-volume production through injection molding.

Part consolidation 

Reduces complexity and assembly requirements. 

Example:

LEGO's modular brick system represents masterful plastic design, with parts molded to tolerances of 10 micrometers to ensure consistent clutch power and interchangeability across billions of bricks.

Structural analysis

Ensures durability with minimal material. 

Example:

Herman Miller's Aeron chair uses glass-filled nylon for critical structural components, with complex ribbing and support structures that provide strength while minimizing material usage, reducing weight by 30% compared to previous designs.

Surface texturing and finishing 

Enhances aesthetics and functionality. 

Example:

Gillette's razor handles incorporate textured thermoplastic elastomers over-molded onto rigid plastic cores, creating ergonomic grip zones that maintain performance when wet while visually communicating where to hold the product.

Design for assembly 

Facilitates efficient manufacturing. 

Example:

Dyson's vacuum cleaners use snap-fit connections and innovative plastic components that reduce assembly time by 75% compared to conventional designs, while maintaining perfect alignment of critical cyclone technology components.

Light-weighting 

Reduces material use without compromising performance. 

Example:

Automotive dashboard manufacturer Faurecia redesigned instrument panels using microcellular foaming technology (MuCell), reducing weight by up to 30% while maintaining structural integrity and Class-A surface quality.

Sustainable Design Considerations

Address environmental impact. 

Example:

Unilever's compressed deodorant bottles use 50% less plastic through wall thickness optimization and redesigned actuator mechanisms, while maintaining the same number of applications as traditional packaging.

Color and transparency

Utilize plastic's unique aesthetic properties. 

Example:

Apple's original iMac used translucent colored polycarbonate housing to transform computers from beige boxes into design statements, with sophisticated techniques to control color consistency across complex curved surfaces.

User-Centered Design

Focuses on human interaction. 

Example: 

OXO's measuring cups feature innovative angled surfaces that allow measurement reading from above without bending, molded from clear Tritan™ copolyester with precisely calibrated markings integrated directly into the plastic.

Tritan™ copolyester is a durable thermoplastic polymer that combines exceptional clarity, dishwasher durability, and impact resistance. It offers high heat resistance while maintaining transparency and withstanding repeated cleaning without clouding or cracking.

Lifecycle Consideration

Addresses a product's entire journey. 

Example:

IKEA's KUGGIS storage boxes are designed with 25% recycled polypropylene content, stackable geometry that optimizes shipping efficiency, and mono-material construction that facilitates recycling at end-of-life.

Effective plastic product design embraces the material's unique capabilities while addressing its limitations, creating solutions that balance performance, cost, manufacturability, and increasingly, environmental responsibility throughout the product lifecycle.