Scientists from TNO at Holst Centre and TNO Climate, Air & Sustainability, together with recycling specialists from MARAS B.V., set out to answer a challenging question: can in-mold electronics (IME) - circuits that are embedded directly into rigid plastic - be repaired instead of discarded? These components power many automotive and consumer products, yet their sealed construction makes repairing them nearly impossible. Failure often means replacement, driving up electronic waste and resource consumption.

Breaking the Seal: A New Method for Disassembly and Repair

The research team developed a specially designed layer that allows IME devices to be dismantled safely. Once opened, damaged circuits could be restored and faulty components replaced. After repairs, the devices were re-encapsulated in plastic and thoroughly tested. The results were encouraging: the refurbished electronics operated almost like new, with only a slight increase in energy consumption: around two percent, within a two-percent error margin.

A Cleaner Footprint: Environmental Gains from Circular Repair

A detailed life-cycle assessment showed that repairing and recycling IME devices, rather than treating them as single-use products, dramatically reduces the environmental impact. Global warming potential was cut by up to forty-one percent, and material savings were significant - silver consumption alone dropped by roughly eighty percent. These outcomes underscore the value of circular design and repair strategies.

Time, Materials, and Money: The Remaining Challenges

Despite the promise, the repair process is not yet economically optimized. Each device currently requires around seventy minutes to repair, along with additional materials and energy. Scaling the approach will likely depend on automation, batch repair techniques, and designing future IME components with easier disassembly in mind.

Toward a Circular Future for Embedded Electronics

Even with current hurdles, the study shows that repairing IME devices is both technically feasible and environmentally beneficial. With further process improvements, automation, and a repair-friendly design, IME repair could evolve into a cost-effective alternative to replacement - supporting the circular economy as well as policy efforts such as the EU’s Right to Repair.

You can find the full publication here:

Repairing of in-mold electronics and life cycle assessment - ScienceDirect