SusPlasPro

The SusPlasPro funding project aims to develop an innovative concept for the mechanical recycling of post-consumer plastic waste (PCR). This waste often consists of complex, heterogeneous plastic composites, which are currently mainly incinerated, resulting in the release of large quantities of CO2. The aim of the project is to enable the recycling of PCR for the manufacture of technical and durable products through a holistic “circular engineering” approach. 

As part of the interdisciplinary joint project, various companies and research institutions are working together to create the technological prerequisites for the efficient processing of PCR. They are investigating how PCR materials can be recycled, processed and used for new products. This also includes the development of methods for characterizing material properties and the optimization of production processes, such as injection moulding. 

Cooperation between industry and science is a key component of the project. Companies such as Gardena Manufacturing GmbH, Aalen University and partners such as Plexpert GmbH and Merkle CAE Solutions GmbH are involved. These partners contribute their expertise in the fields of plastics processing, simulation technology and materials research in order to develop practical solutions. 

Ultimately, the project aims to help reduce the environmental impact of plastic waste, reduce the use of virgin materials and promote a circular economy that meets the objectives of the EU's Green Deal. The development of practice-oriented guidelines for the processing of PCR should enable broad industrial use in the future and lead to sustainable product development. 

Merkle CAE Solutions GmbH is responsible for the following tasks in the project: 

• Demonstrator geometry development under recycling aspects. 
• Material modeling (mechanical properties). 
• Structural simulation for the calculation and optimization of molded parts. 
• Topology optimization for the most resource-efficient product design possible. 

Merkle CAE Solutions is responsible for the structural-mechanical design of dynamically stressed plastic components and the simulation of material behavior, especially in connection with the processing of PCR materials (post-consumer recyclates).