TECOS – the Slovenian Tool and Die Development Centre – provides engineering services that support both domestic and international partners in product development, from concept to production. TECOS offers a comprehensive and complementary range of services, including plastic injection molding simulations, metal forming simulations, conformal cooling and metal 3D printing, 3D scanning and reverse engineering, optical 3D measurements and metrology, FEA structural analysis, prototyping, material development, small-series plastic injection molding, and technology transfer.
As a partner in the CIRCOTRONIC project – a Transnational Network of Circular Labs for Electrical and Electronic Equipment (Interreg Central Europe) – TECOS collaborates with other project partners to reduce environmental impact and implement circular approaches in the production of electrical and electronic equipment (EEE). The project aims to identify EEE-related challenges and develop sustainable, circular-oriented solutions and best practices that help reshape manufacturing in Central Europe. This includes streamlining processes, improving value chains, designing sustainable products and services, and reducing the environmental footprint of EEE production. TECOS also integrates these circular goals into its regular operations through collaborations with various clients.
ULLA – Development of a Smart Hydration Reminder
ULLA is a smart gadget that reminds users to stay hydrated and is the result of TECOS’s product development efforts. In collaboration with ULLA Labs, TECOS designed the plastic components of the product to meet several key requirements:
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Easy assembly and disassembly
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Compatibility with any glass or bottle
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High toughness to prevent breakage when dropped
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Smooth, rounded shapes for comfortable, frequent handling
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Use of skin-safe materials with no irritation or chemical migration
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Functionality in a temperature range of -20°C to +50°C
During the design phase, both technological and material constraints were carefully considered. Initially, food-grade polypropylene (PP) was selected as the injection molding material.
The complete product consists of five components: the electronic circuit, battery, attachment strap, top casing, and bottom casing. The lower casing is designed for intuitive insertion of the electronic circuit and battery, which prevents incorrect assembly. TECOS was responsible for the full product and mold design, as well as the series production of the plastic components.
ULLA – A Smart Hydration Reminder with Added Circular Value
In the next development phase, TECOS and ULLA Labs initiated a follow-up project to integrate CEPLAFIB recycled materials into high-tech products. Originally made from virgin plastic, ULLA was redesigned to incorporate environmentally friendly materials in line with circular economy and sustainable development principles. The redesigned product was developed in collaboration with the CEPLAFIB consortium, which created a new composite material made from post-consumer plastic packaging and waste newspaper. This cellulose fiber–reinforced recyclate is suitable for advanced applications in the automotive, packaging, and construction sectors.
Through this partnership, TECOS and ULLA Labs developed the first ULLA device made entirely from 100% recycled plastic and newspaper fibers. By optimizing the ratio of recycled plastic to paper fibers, the material’s elastic modulus can be increased by up to 210%, and the strength of the final products improved by up to 40%.
Transferring Best Practices to the EEE Sector
The development of the fully recycled ULLA device serves as a practical example of how best practices in circular product design can be transferred to the electrical and electronic equipment (EEE) sector. The ULLA project illustrates how innovative design and cross-sector collaboration can produce high-value, lower-impact products compared to those made from virgin materials. With 100% recycled content, TECOS and ULLA Labs demonstrate that circular economy principles are not only viable but valuable in high-tech product development.
ULLA is more than just a reminder to stay hydrated – it’s a symbol of sustainable thinking in engineering and product innovation.