In the traditional linear economy, products are manufactured, used, disposed of and recycled in an unsustainable manner. This is particularly evident with plastic products, which are often not recognized as valuable resources at the end of their life cycle. This linear approach leads to climate change, resource wastage and environmental pollution. While there are many solutions to the challenges of a linear economy, one of the most crucial yet often overlooked aspects is design.

Despite being less associated with the chemical industry or the circular economy, design plays a pivotal role in fostering circularity through various methods, as noted by experts at polymer materials manufacturer Covestro. The chemical industry holds a unique position in the value chain, bringing essential knowledge about materials into design discussions, thereby presenting a significant opportunity.

"The design phase determines a large part of a product's environmental impact: from the choice of materials to repairability, from a long and useful product life to recyclability. We therefore can't understate the topic of design when we want to become fully circular," said Christopher Stillings, head of color and design at Covestro's engineering plastics business unit.

Covestro, based in Leverkusen, Germany, has committed to becoming fully circular with ambitious climate targets to achieve net zero emissions by 2050. This means net zero not only in its own operations and purchased energy but also in its upstream and downstream supply chain. This requires the company, among other efforts, to supply an increasing number of low-carbon-footprint products to downstream industries, which will involve more advocacy for circular design.

"As materials experts early in the value chain, we at Covestro sit in the sweet spot to consult our customers and partners on how to use circular design principles when conceiving a product. We want to systematically collaborate with designers to make use of that," Stillings added.

Circular trend

While the concept of product design is not new, a shift is happening worldwide due in part to regulators placing increasing emphasis on the topic. For example, the European Union is tightening its requirements for environmentally friendly product designs and has approved new rules to make products sold in the EU more reusable, repairable, upgradeable and recyclable. A new proposal by the German Institute for Standardization for a method to achieve circular design of products is on its way. In the United States, the Department of Energy is pursuing its Strategy for Plastics Innovation, which also includes the factor of recyclability by design.

To use that momentum, Covestro offers expertise and solutions on multiple fronts of circular design. For example, the company is digitalizing the sampling processes to support dematerialization — a key aspect of circular design. With the company's latest Imagio CQ digital sampling tool, designers can swiftly capture essential visual characteristics like the color, gloss, opacity and texture of a certain material formula through 3D renderings of product designs.

The company is also an expert in design for longevity. As a high-performance materials manufacturer, Covestro provides polymer materials for cars, buildings and the cold chain that have a lifetime of several decades.

The use of circular raw materials with a low-emission footprint is also Covestro's strength, making products made of such materials more circular from the start.

The company's strength in circular design was exemplified in June at Design Shanghai, a prominent design event, where Covestro exhibited its latest solutions — from materials and design know-how to digital tools — that support designers in working for circularity. Its participation also featured more than a dozen workshops with a lineup of designers and partners, including RAL Colours, Chris Lefteri Design and Tongji University.

"At Covestro, we are adept at connecting circularity and aesthetics through our expertise in sustainable materials and design, and our commitment to achieving full circularity," said Emily Shi, global business development manager of color and design at the engineering plastics department and Covestro's project manager for Design Shanghai. "Our engagement with designers, partners and customers at Design Shanghai has been overwhelmingly positive, underscoring the growing importance of circular design within the design community as it rises up to the challenge of creating a more sustainable future."

Among the exhibits were new hair dryers made by Shanghai Tonney using more sustainable materials, including a partially bio-based waterborne coating raw material and post-consumer recycled polycarbonate from Covestro.

"Low-carbon products are one of the edgy topics in the design field. Through technological innovations, Covestro advances the use of alternative raw materials to replace fossil-based raw materials in our production and reduces products' carbon footprint, which coincides with the trendy hot spots in the design field," said Anand Khot, head of coatings and adhesives in the Asia-Pacific region at Covestro.

Shanghai Tonney, a Chinese supplier to the hospitality industry, and Covestro first met at Design Shanghai 2023. The speed of the cooperation showcases the willingness of Chinese companies to implement circular design.

"At Tonney, we are exploring ways to leverage material technology to reduce the carbon footprint of our products while maintaining product stability and appearance to enhance the consumer experience," said Zhang Hongbin, chairman of Shanghai Tonney. "The integrated sustainable material solutions from Covestro are helping us drive environmental, social and governance development in the hospitality industry and promote a low-carbon travel lifestyle for consumers."

Other highlights included translucent leisure chairs and a 3D-printed jellyfish-shaped lamp made of recycled polycarbonate plastics. These showcased how Covestro, through its color, material and finish expertise, aims to integrate aesthetic design into the development of sustainable materials in everyday life. The inherent beauty of such recycled polycarbonate, produced from recycled water barrels without any added color, was prominently displayed.