Eco-design and Manufacturing of Green In-Mold Electronics (IME)
The CIRC-UITS pilot explores how IME technologies can be redesigned and manufactured according to circular economy principles, improving sustainability without compromising functionality.
In-Mold Electronics (IME) is an emerging technology that integrates electronic circuits directly into plastic components. IME solutions are increasingly used in automotive interiors, consumer electronics and smart surfaces because they allow designers to create thinner, lighter and more functional products. However, the integration of electronics into plastic components creates significant challenges for repair, reuse and recycling. Pilot 3 explores how IME products can be developed using circular design strategies that improve repairability and sustainability while maintaining technological performance.
The pilot evaluates manufacturing processes, material choices and repair techniques for flexible electronics, demonstrating how IME technologies can become part of a circular electronics ecosystem rather than contributing to complex waste streams.
Objectives
The pilot aims to:
Develop circular design strategies for IME components and manufacturing processes.
Improve repairability and remanufacturing potential of IME devices.
Evaluate environmental impacts using Life Cycle Assessment methodologies.
Demonstrate digital tools that support circular decision-making for flexible electronics.
Key Activities
The pilot includes several technical developments:
Investigation of repair techniques for IME components.
Testing of materials and manufacturing processes that support circular design.
Development of digital models and tools supporting sustainability analysis and decision support.
Collaboration between research organisations, electronics manufacturers and recyclers.
These activities enable the evaluation of circularity potential for next-generation flexible electronics technologies.
Results
The pilot successfully demonstrated:
Repair strategies for IME components.
Methods to improve design for disassembly and repair of integrated electronics.
Digital tools supporting sustainability evaluation of electronics manufacturing processes.
Greater understanding of circular opportunities within the flexible electronics industry.
Impact
IME technologies are expected to become increasingly widespread in automotive and consumer electronics. The results of this pilot provide guidance on how these technologies can be developed sustainably from the start, ensuring they support a circular electronics ecosystem.
The pilot contributes to improving the sustainability of flexible electronics by introducing circular design practices into an emerging technology field. By enabling repair and more efficient material use, the pilot reduces environmental impacts associated with electronics embedded in plastic products.
In the long term, the results support the development of sustainable flexible electronics industries, ensuring that innovative technologies are designed with circularity from the outset rather than requiring costly redesigns later.
Relevance for SMEs
SMEs are key players in the flexible electronics and advanced manufacturing sectors. The solutions developed in this pilot provide SMEs with guidance on how to integrate circular design strategies into the development of next-generation electronic products.
For small technology companies and manufacturing suppliers, this creates opportunities to develop repair services, specialised materials and innovative manufacturing processes that support circular electronics production. By adopting sustainable IME solutions early, SMEs can strengthen their position in emerging markets for smart surfaces and integrated electronics.