COMMENT
Connectivity meets sustainability
By Tristan Stubbs, mechanical engineer at Bulgin U
ninterrupted power in harsh environments is essential across numerous industries, from agriculture and food preparation to transport and infrastructure. However, balancing the need for reliable connectivity with the growing demands for sustainability in various sectors can be challenging, especially when safety is a concern. This article discusses how even minor adjustments in product development – including switching to bio-based carbon sources – enables the development of more eco-friendly environmentally sealed connectors and electrical components without compromising on technical performance.
Ever-present environmental challenges
Outdoor environments expose electrical components to relentless conditions that can compromise their integrity. Electrical connectors must be able to withstand a range of environmental stresses – from rain and snow to extreme temperature variations and high pressures – all year round, testing their strength and robustness. This can be in common settings, such as to more extreme applications like oil and gas operations.
Sealed protection for reliable performance
Connectors in these environments are typically sealed, feature IP68-rated protection – showing resistance to dust and water – and are designed to meet these challenges head on. This level of protection both dry settings and locations subject to heavy rain or submersion. Many are also constructed with UV-resistant materials that are protected from degradation by sunlight, even after prolonged exposure. This durability ensures that components maintain their structural integrity and functionality over years of outdoor use, offering peace of mind and continuous connectivity, regardless of environmental stressors.
When designing connectors for these environments, it’s vital to choose materials that are proven to withstand the test of time and the forces of nature. The outer
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shell of the connector is perhaps the most important component, as it’s this section that is exposed to the environment, providing protection against impact and damage for the electrical contacts contained within. In these settings, the outer shell forms the greatest part of the impermeable barrier, and must be designed in a way that allows rubber glands and O-rings to seal any gaps that might otherwise allow the ingress of water. Metal would traditionally have been used because of its durability, resilience to high temperatures and high mechanical strength. However, its cost, weight and tendency to corrode when exposed to water for extended periods has meant that metals have largely been replaced by plastics, which are cheaper to produce, weigh less and offer more options for customised design.
Bio-based alternatives on the rise Bio-based plastics are a promising alternative as they use carbon compounds derived from more renewable sources, such as corn, cellulose, biomass waste, vegetable oil, etc, than the traditional fossil fuels like crude oil. Although their application in industry remains quite limited, the global bioplastics market size is expected to increase at a CAGR of 19.5 per cent from 2025 to 2030. This growth is primarily driven by growing concerns over traditional plastics, and government regulations restricting the
NOVEMBER 2025 | ELECTRONICS FOR ENGINEERS
consumption of petrochemicals in certain applications. This comes as no surprise, as bio-based plastics offer unique advantages over traditional plastics, reducing our reliance identical to their fossil fuel counterparts. One study even concluded that substituting Europe’s annual demand for fossil-based polyethylene (PE) with bio-based PE would
save around 73 million tonnes of CO2. While electrical connectors encompass a small overall share of plastics consumption, the onus falls on manufacturers to investigate all options to reduce their environmental impact. In reality, even small changes can make a difference over time, especially considering the ubiquity of these components. This has led companies such as Bulgin to develop new product lines, including its Standard Vitalis Buccaneer.
Forward-thinking companies are increasing their R&D investment in bio-based materials, adopting them to replace, or complement, existing products made from traditional plastics. While chemically the same, these materials present a unique opportunity: they deliver the same mechanical performance – including durability and resistance to harsh environments – while offering improved environmental credentials. In doing so, they help to reduce carbon emissions and make a meaningful contribution to global sustainability efforts.
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