Upcycling plastic waste: Sustainable and customized injection molding for a circular economy

Project summary

One of today’s most pressing environmental issues is the growing amount of plastic waste. Although the problem has been recognized for decades, effective solutions are still lacking. Global plastic production exceeded 400 million tons in 2022, but only 8.9% was recycled. This extremely low rate highlights the urgent need for new, innovative approaches. In the European Union, strict regulations have been introduced to promote recycling, but the necessary technologies are still under development. Our research group is working to provide practical answers to this challenge by developing novel processing techniques that allow plastic waste to be transformed into valuable new products. Instead of simply reusing the material, our aim is upcycling—giving waste plastics a second life in the form of strong, functional, and lightweight parts. We are experimenting with foam injection moulding and the production of fibre-reinforced components using recycled packaging and textile waste. These methods reduce raw material consumption and can improve product quality compared to traditional recycling. We also examine how newer, more cost-effective injection moulds can support this process. Our ambition is to demonstrate that recycled materials can be used reliably in industrial production. The long-term goal is to support a more circular, resource-efficient plastic industry, where waste becomes a raw material for high-quality products.

Project results