SUSTAINABILITY
Resilient and responsible connectivity
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By Tristan Stubbs, mechanical engineer at Bulgin ontinuous power in exposed
environments is critical across industries such as agriculture, food production, transport and infrastructure. In these sectors, equipment must operate safely and reliably despite challenging outdoor conditions. At the same time, manufacturers face increasing pressure to reduce environmental impact and transition towards more sustainable materials. Even relatively small adjustments in product development, such as the use of bio-based carbon sources, can help environmentally sealed connectors to meet both performance and sustainability expectations.
Resilience in harsh environments Outdoor electrical components are subject to constant environmental stresses, including and mechanical strain, which can all affect the long-term integrity of connectors. These conditions are encountered in everyday outdoor lighting, as well as more demanding settings including solar farms and wind turbine systems.
To withstand such harmful factors, connectors are typically designed with IP68- rated sealing to prevent dust ingress and tolerate water submersion. Comprehensive
sealing systems using compression glands and O-rings help to create an effective barrier against moisture and particulates. UV-resistant materials are also commonly degradation during prolonged exposure to sunlight.
Together, these design features help to maintain structural integrity and electrical connectivity over extended periods of outdoor use.
Advanced sealing and enclosure strategy
Material selection is central to connector performance, as the outer housing acts as the primary defence against environmental and mechanical impacts, protecting more vulnerable internal contacts. Metals were traditionally favoured for housings due to their strength, high temperature tolerance and mechanical robustness, but their weight, higher manufacturing costs and susceptibility to corrosion in wet environments have led many designers to adopt engineered plastics instead. Modern climate-resistant polymers offer comparable strength while reducing weight, improving costs. Durability is not only a technical consideration but also a sustainability factor.
Connectors that maintain performance over longer lifetimes require less frequent replacement and maintenance, helping to reduce material waste and overall resource consumption.
Renewable polymers gain traction While high performance plastics provide grades are derived from fossil fuel feedstocks. Their production is associated with greenhouse gas emissions and the depletion regulations and increased scrutiny of supply chains are prompting manufacturers to shift their attention towards lower-carbon alternatives.
Bio-based plastics are gaining traction as one potential solution. These materials use carbon sourced from renewable feedstocks, such as corn, cellulose, biomass waste and vegetable oils. Importantly, they are chemically identical to fossil-based polymers, allowing them to deliver the same mechanical properties and processing characteristics required for demanding industrial applications. Although their use is currently limited, the global bioplastics market is projected to grow at a compound annual rate of 19.5 per cent between 2025 and 2030. Research indicates that replacing Europe’s annual consumption of fossil-based polyethylene with bio-based equivalents could reduce emissions by approximately 73
Conclusion
Sustainability is becoming a central priority across the engineering sector, and companies are increasing investment in bio-based polymers to replace or complement plastics derived from fossil fuels. These materials are chemically identical to traditional grades, and deliver the same mechanical strength, durability and resistance required in harsh environments. Incorporating bio-based materials into established designs therefore allows manufacturers to achieve high performance standards, while reaching long term sustainability and decarbonisation goals.
24 MARCH 2026 | ELECTRONICS FOR ENGINEERS
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