ENSO - Built to Return

Was es macht

ENSO is a modular suitcase system made from just three materials that are fully separable and mono-material recyclable. With repairable construction and a digital material passport, it redefines products as circular, responsible systems.

Deine Inspiration

The idea for ENSO emerged from questioning why everyday products - like suitcases - are so hard to repair or recycle and often end up in the waste. Inspired by the growing issue of material complexity and planned obsolescence, the project began with an analysis of industrial history and product design systems. The insight: true sustainability isn’t just about better materials, but about rethinking how products are built, used, and returned. ENSO was developed as a response - a modular suitcase system that demonstrates how circular design principles can be practically applied without compromising function or aesthetics.

So funktioniert es

Its modular design uses reversible screw connections, allowing components to be easily separated, repaired, or replaced. The shell is made from durable, fully recyclable CURV® polypropylene; wheels and grips are made from bio-based vitrimer plastic from polyhydroxyalkanoates (PHA), enabling natural compostation, with all parts connected using stainless steel. Materials are mono-material and cleanly separable, enabling effective end-of-life recovery without glues, foams, or composites. Handles, locks, and hinges are integrated into the shell to reduce weak points. A digital material passport provides repair guides, material origins, and circular return options. The modular system allows the suitcase to grow with the user’s needs. ENSO’s design and service model extend lifespan and create a circular system focused on longevity, transparency, and responsibility.

Designprozess

The design process behind ENSO began with a critical examination of modern consumer products—specifically how material complexity, short product lifespans, and non-repairable constructions hinder sustainability. A suitcase was chosen as a symbolic and practical example: widely used, often short-lived, and rarely recyclable. The early phase focused on research into historical production methods, circular economy principles, and the systemic challenges of planned obsolescence. Material studies and disassemblies of existing suitcases revealed key failure points—especially in externally mounted components like wheels, handles, and hinges. In response, ENSO was developed as a fully modular system, where every component is designed for separation, repair, and recyclability. Numerous prototypes explored connection strategies—from snap-fits to bio-based adhesives—before settling on stainless steel screw fittings for durability and reversibility. Material selection prioritized mono-materials with high recovery potential, such as recycled CURV® polypropylene and PHA-based elastomers. The design followed the function and hightlights the adaptability and modularity. Form, function, and lifecycle were developed simultaneously.

Warum es anders ist

ENSO challenges the way products are traditionally designed by shifting focus from object to system. Unlike conventional suitcases made from mixed materials and glued components, ENSO is built from mono-material parts that are fully separable, repairable, and recyclable. Its modular design allows users to adapt size and function over time - extending use, reducing waste, and avoiding replacement. Instead of hiding wear-and-tear, ENSO embraces transparency: all components are accessible, replaceable, and tracked through a digital material passport. Even design details follow this thinking - handles, locks, and hinges are integrated into the structure to reduce weak points. ENSO is not just a product; it’s a proof of concept for how circularity can be embedded from the very first sketch to the last screw. In a market driven by fast turnover, Enso reclaims longevity, responsibility, and adaptability as core design values

Pläne für die Zukunft

The most important next steps for this project are refining the modular system for scalable production and conducting real-world durability testing - particularly testing full-scale prototypes against harsh airport handling to observe material performance. Equally crucial is developing a solid business plan that evaluates target markets and how the product’s system will function in real-life scenarios, identifying potential weak points. A pilot program with users can validate functionality, emotional attachment, and system impact, laying the groundwork for a fully circular product-service model.

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