Monday, 19 January 2026

20 Mental Models for effective thinking in- and outside the plastics industry

Hello and welcome to a new blog post. Today we cover mental models and why the are not only important for us in polymer engineering, but also for private and other professional areas of life too.

In 2026, mental models—conceptual, often simplified frameworks for understanding the world—are critical for navigating a landscape defined by rapid AI advancement, geopolitical instability, and extreme information saturation. They serve as "cognitive toolkits" that allow individuals and leaders to parse complex, ambiguous data into actionable decisions. 

Mental models are important in 2026 for the following key reasons:

1. Navigating Complexity and AI-Augmented Environments

  • Example - Cutting Through "Noise": With AI generating massive amounts of data, mental models help filter information and focus on high-impact factors (e.g., using the Pareto 80/20 Rule to identify crucial data points).
  • Example - Contextualizing AI Outputs: As AI becomes ubiquitous in 2026, human judgment remains essential for interpreting AI insights; mental models provide the necessary framework for this contextualization.
  • Example - Systems Thinking: Understanding how different components (remote work, global supply chains, AI tools) interact is crucial. Systems thinking helps identify patterns and leverage points for change rather than reacting to symptoms. 

2. Professional Adaptability and Decision Speed

  • Example - Rapid Decision Making: In 2026, business leaders must make decisions 2.5 times faster than competitors. Mental models (like the OODA Loop—Observe, Orient, Decide, Act) enable swift, effective, and reasoned actions under pressure.
  • Example - Mitigating Cognitive Bias: The fast-paced environment increases the risk of emotional or faulty decision-making. Mental models like Inversion (considering how to avoid failure) or Second-Order Thinking (evaluating long-term consequences) allow for more objective, strategic choices.
  • Example - Increased "Model Literacy": Success in 2026 requires understanding multiple mental models across disciplines—a "latticework" that allows for more versatile, creative problem-solving rather than relying on a single, outdated framework. 

3. Personal Resilience and Growth

  • Example - Managing Cognitive Load: The sheer volume of information can cause "cognitive fatigue." Mental models help organize information and reduce the mental effort required to make sense of new, complex situations.
  • Example - Developing Emotional Stamina: As global instability creates stress, mental models assist in building emotional resilience and maintaining a "growth-oriented" perspective, allowing individuals to adapt to change rather than being overwhelmed by it.
  • Example - Lifelong Learning: In 2026, continuous learning is essential for career longevity. Mental models facilitate the learning of new concepts by connecting them to existing knowledge, accelerating the transition from novice to expert. 

4. Improved Collaboration 

  • Example - Shared Mental Models: In hybrid and remote work environments (which are standard by 2026), shared mental models enable teams to align on goals and expectations, leading to more cohesive and efficient collaboration. 

My 20 Mental Models for Effective Thinking

Over the past decade of my career in polymer engineering, I have systematically collected and applied a range of mental models to enhance my professional effectiveness. In the accompanying sketchnote (Figure 1), I have outlined the 20 mental models I utilize most frequently. 

These models are categorized into four key areas: Core Frameworks, Decision Making and Bias, Change and Adaptation, and System and Interaction.

Figure 1: 20 Mental Models for effective thinking in- and outside plastics industry

In summary, as we move through 2026, mental models are no longer optional, abstract concepts; they are the essential, daily tools for maintaining clarity, speed, and sanity in a rapidly evolving (plastics) world. 

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://tetr.com/blog/mental-models-for-business-success-secrets-for-aspiring-founders#:~:text=Mental%20models%20are%20cognitive%20frameworks,identify%20patterns%20others%20might%20miss.

[2] https://taproot.com/mental-models/#:~:text=Simplifying%20Complexity:%20In%20today's%20fast,productive%20discussions%20and%20innovative%20solutions.

[3] https://medium.com/@chamiduweerasinghe/the-future-of-personal-development-trends-to-monitor-in-2026-and-beyond-0537609878f8#:~:text=Companies%20that%20invest%20in%20building,Technology%20as%20the%20Growth%20Engine

[4] https://academic.oup.com/ct/article/35/4/250/8166013#:~:text=These%20models%20map%20onto%20elements,.%2C%202004%2C%202007).

Friday, 9 January 2026

AI & Machine Learning Transforming the Plastics Value Chain

Hello and welcome to a new blog post. AI and machine learning are rapidly transforming every stage of the plastics value chain—from material innovation to recycling and sustainability. 

Introduction

Just as elephants in Africa can sense approaching storms and tsunamis before they arrive—prompting smaller animals to follow their lead—the plastics industry is witnessing its own early warning signs. Today, the “big elephants” of the economy—major tech companies—are already on the move, rapidly embracing AI and machine learning to transform every stage of the plastics value chain. If we want to keep pace and avoid being left behind, now is the time to act.

AI & Machine Learning Transforming the Plastics Value Chain

In this sketch note, I explore how AI is accelerating polymer research, revolutionizing part design, optimizing manufacturing, and enabling smarter, more sustainable choices across the industry. 

Whether you’re in R&D, engineering, production, or sustainability, discover practical examples and key takeaways on how AI is reshaping the future of plastics. 

Don’t wait for the storm to hit—see how your organization can leverage these advancements for a competitive edge!

AI and Machine Learning: Transforming the plastics value chain.

1) AI & Machine Learning Transforming the Plastics Value Chain

Material Development and Polymer Innovation

AI and machine learning (ML) are actively accelerating materials research, enabling predictive modeling of polymer properties, virtual screening of candidates, and synthetic data generation to overcome experimental gaps. This approach dramatically speeds up the discovery of sustainable and high-performance plastics. 

In advanced research, machine learning models have been used to design crosslinker strategies that strengthen polymer networks and could be applied to real industrial plastics to reduce waste and extend service life. 

Emerging tools are focused on materials that combine sustainability with performance (e.g., biodegradable or recyclable polymers), addressing long-standing limitations in replacing conventional plastics. 

Practical engineering implications

  • R&D teams can leverage AI to predict key material properties like glass transition temperature or tensile strength without exhaustive lab trials.
  • Material selection and optimization become data-driven, reducing development cycles and enabling tailored polymer solutions in automotive, medical, and packaging applications.

2) AI in Part Design, Material Selection & Engineering Decision Support

AI platforms such as plastics.ai offer curated, domain-specific expert knowledge tied to practical plastics technology (including material choice, defect mechanisms, processing answers) with transparent source backing — a major shift from generic LLMs toward validated engineering assistance. 

ML-augmented digital twin technologies and simulations can reduce prototype cycles by allowing engineers to explore variations in part geometry, polymer grades, and processing conditions in silico before physical testing. 

Practical engineering implications

  • Engineering design teams can integrate AI tools to automate material performance predictions, compare alternatives, and flag potential manufacturability issues before mold design and process planning.
  • AI-assisted design accelerates concept-to-production timelines and supports optimized material selection for durability, weight, and recyclability trade-offs.

3) AI & Digitalisation in Processing and Production

Autonomous Injection Molding (Processing Optimization)

Companies like ENGEL are showcasing inject AI and autonomous injection moulding cells — systems that continuously analyze over 1,000 process parameters, adjust cycle conditions in real time, and reduce scrap and setup times. 

These systems embed decades of application engineering into the control layer, making consistent quality achievable without deep expert intervention on the shop floor. 

Practical engineering implications

  • Process engineers can use AI to reduce dependence on individual experts by capturing and distributing best-practice expertise across operations.
  • AI-based control enables zero-defect strategies, consistent cycle times, reduced energy use, and lower reject rates — directly impacting productivity and sustainability goals.

Predictive Maintenance & Process Automation

Across manufacturing, AI is deployed for predictive maintenance, where sensors and ML forecast equipment degradation before failures, cutting unplanned downtime. 

Practical engineering implications

  • Maintenance planning shifts from reactive to proactive, increasing uptime, extending machine life, and enabling better capacity planning.

4) AI & Recycling, Circularity, and Sustainability

Sorting and Recycling Optimization

AI and ML-enhanced spectroscopic sorting solutions are improving accuracy and throughput in recycling streams, particularly for mixed plastics — a major bottleneck in circularity. 

Research labs and industry collaborations are building AI-driven frameworks that interconnect data from recycled feedstocks to packaging production, choosing optimal processes in real time for quality outcomes. 

Practical engineering implications

  • Recycling engineers benefit from higher fidelity sorting, reducing contamination and increasing recyclate quality, supporting higher recycled content in products.
  • Real-time decision tools enable processors to adapt extrusion, molding, or compounding recipes depending on fluctuating quality of input recyclates.

Circularity Platforms & Tools

The launch of tools like the KIKS open beta platform applies machine learning to the entire value chain, offering material substitution suggestions, predictive property data, and analytics support for composite design and sustainable choices. 

Practical engineering implications

  • Value chain stakeholders — from compounders to OEMs — can streamline sustainability decisions, evaluate alternatives rapidly, and reduce reliance on manual material data curation.

5) Sectoral & Strategic Impact (Industry Outlook)

Broader industry data (e.g., Deloitte chemical industry outlook) indicates that AI and digital technologies are a core element of resilience and transformation strategies for the chemicals and plastics sectors amidst economic uncertainty. AI is increasingly used to optimize operations, reduce energy consumption, enhance safety, and accelerate commercialization of new materials.

Practical engineering implications

  • Companies that embed AI in R&D, process platforms, and end-to-end digital strategies will be best positioned to navigate market volatility and regulatory pressures.
  • Digital maturity — including AI integration — is becoming a competitive differentiator rather than optional IT add-on.

6) Challenges & Enablers for SMEs and Engineering Organizations

Adoption barriers remain significant for small and medium enterprises (SMEs), including data quality issues, lack of expertise, and legacy system incompatibility. However, public funding programs and strategic digitalization roadmaps can ease adoption and unlock competitive benefits. 

Practical strategies emphasize starting with low-code and cloud-based AI tools, aligning with current IT environments, and focusing on use cases that return near-term value (e.g., predictive maintenance or energy management) before scaling. 

Practical engineering implications

  • Polymer engineers and operations leaders in SMEs should prioritize pilot AI projects aligned with measurable KPIs to justify investments and build internal experience.
  • Collaboration with digital partners or industrial research consortia can reduce cost and expertise barriers.

Key Takeaways for Polymer Engineering Practice

  • Material Innovation: AI accelerates materials discovery, reduces time-to-performance validation, and supports sustainable alternatives.
  • Design & Selection: Data-driven tools enhance part design, material decisions, and early manufacturability assessment.
  • Processing: AI-augmented process controls and autonomous systems improve production stability, quality, and efficiency.
  • Recycling & Circularity: Intelligent sorting and integrated data frameworks enhance recyclate use and circular outcomes.
  • Strategic Competitive Advantage: AI is now foundational to operational excellence, innovation leadership, and resilience in the plastics sector.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Thursday, 8 January 2026

Energy Consumption in Plastic Injection Molding: Hydraulic vs. Electric Machines (Rule of Thumb)

Hello and welcome to a new Rule of Thumb post (check out other Rule of Thumb posts here).

When it comes to plastic injection molding, energy efficiency is a key factor in both operational costs and sustainability. Let’s take a closer look at how different machine types compare:

If we set the energy consumption of traditional hydraulic injection molding machines with constant pumps as the baseline (100%), machines equipped with servo pumps already offer a significant improvement, consuming only about 54–55% of the energy. All-electric injection molding machines go even further, using just 48–49% of the energy compared to standard hydraulics.

However, machine selection should always be based on your specific production needs. In some cases, the part you want to mold may be better suited to a hydraulic machine with a servo pump, making this a perfectly valid choice despite the slightly higher energy usage.

In summary, while electric machines lead in energy efficiency, the best solution is always the one that fits your application requirements.

Figure 1: Energy consumption of hydraulic vs electric injection molding machines.

Literature: 

[1] https://www.findoutaboutplastics.com/2023/01/major-benefits-of-plastics-for.html


Wednesday, 7 January 2026

5 Common Mistakes to Avoid When Selecting Polymers for Electric & Electronics Applications

Hello and welcome to a new post. In today’s post, we discuss five common mistakes to avoid when selecting polymers for electric and electronics applications such as connector housings.

Proper polymer material selection is the most effective antidote for battling plastic part failure and my aim is to help the plastics community to increase their confidence in material selection, especially with high performance polymers and recycling plastics. 

Avoid these 5 common mistakes when selecting polymers for electric and electronics applications

1️⃣ Ignoring Electrical Properties

-Failing to check dielectric strength, insulation resistance, and tracking resistance (CTI) can lead to electrical failures or safety hazards.

2️⃣ Overlooking Flame Retardancy Requirements

-Not verifying compliance with standards like UL 94 V-0 can result in non-compliant products and increased fire risk.

3️⃣ Neglecting Chemical and Environmental Resistance

-Forgetting to assess resistance to chemicals, moisture, and environmental stress can cause premature degradation, corrosion, or loss of performance.

4️⃣ Disregarding Dimensional Stability and Creep

-Choosing materials that warp, shrink, or deform under heat or load may compromise connector fit, function, and reliability over time.

5️⃣Underestimating Processability and Manufacturability

-Selecting polymers that are difficult to mold, have poor flow, or are incompatible with existing tooling can lead to defects, higher scrap rates, and increased production costs.

Figure 1: 5 common mistakes to avoid when selecting plastics for electrical applications.

Literature: 

[1] https://www.findoutaboutplastics.com/2025/04/nature-is-built-on-5-polymers-modern.html