Innovative Process for Recyclable In-Mould Electronics

Fraunhofer IZM Develops Recyclable, Resource-Efficient Injection Molding Process for Electronics

Image: symbol image from the MULTIMODE website; Copyright: multimold.eu

The MULTIMOLD project develops sustainable processes that enhance recyclability and energy efficiency in electronics production. Copyright: multimold.eu

07.03.2025

Making injection-molded electronics more environmentally friendly while providing developers with greater design freedom is a key challenge for the industry. The EU-funded MULTIMOLD project brings together research teams from Fraunhofer Institute for Reliability and Microintegration IZM and international partners to develop an innovative injection molding process that combines advanced electronic functionality with high environmental standards.

Focus on Sustainability: Eco-Friendly Manufacturing

Fraunhofer IZM is analyzing the entire lifecycle of this new technology within the project. Through targeted material analyses and resource-efficient manufacturing processes, the environmental impact is minimized. The goal is to develop a high-performance production technique that is both energy-efficient and recyclable.

Image: MULTIMOLD group; Copyright: R2M Solution

Experts from various fields join forces to advance environmentally friendly injection molding technologies under the MULTIMOLD initiative. Copyright: R2M Solution

Challenges of Conventional Methods

Current technologies for manufacturing in-mold electronics often struggle to meet modern environmental standards. One major challenge is the difficulty in recycling embedded sensors, which are firmly integrated into the polymer. The MULTIMOLD project addresses this issue by:

Developing new methods for separating and reusing individual component layers
Enhancing recyclability through optimized material combinations
Reducing energy consumption and emissions in production

Image: first demonstration for an automotive use case, showcasing recent advances in the development of sustainable and user-friendly human machine interfaces. Copyright: Nanogate Central and Eastern

This component demonstrates for the ‘Automotive’ use case how advanced injection molding techniques can integrate electronic functionality while maintaining high sustainability standards.

New Technologies for Easier Recycling

Plastics Europe calls for immediate action to enhance the EU's competitiveness and support the transition to circular plastics. Proposed measures include:

Mandatory recycled content targets for plastics.
Simplified permitting processes for low-carbon industrial installations.
Recognition of innovative recycling methods, including chemical recycling.
Monitoring and certification schemes to ensure imports comply with EU standards.

Virginia Janssens, Managing Director of Plastics Europe, highlighted the need for streamlined regulations: "To avoid a worrying slowdown in Europe's transition we need urgent measures to make investments in circular plastic production more attractive."