The value of imperfection in industrial product.

This paper explores the defects during the production seen as a gain in usability and an economic opportunity for the industry; the strategy proposed here is to exploit the flaws as generator of unique products and inspiration for the mass customization. These defects, connected to each process, usually entail the removal of the product from the production chain, up to its elimination. Yet even EU directives on guarantees for consumer goods have focused on the lack of conformity of products [Directive 1999/44/EC] or ISO regulations, the usefulness to support Quality Management System [ISO 9001:2008] and authorize and propose strategies for enhancement of the defective products. Therefore this research suggests the involvement of industrial design in the optimization of defects in design and construction in the categories proposed by D.M. Bryce, in order to extend the life of the product from the production stage “This is what we want to do with design: discover and show opportunities” [22], acting primarily on the aesthetic and functional aspect. The method used begins with the identification of possible defects, examining the injection moulding process as a case study. The defects (coming from the state-of-art analysis, interviewing experts and visiting companies) were mainly analyzed critically and creatively interpreted: how do they look aesthetically, what are the causes of their defects, the implication on the moulded part, possible new uses and purposes, etc. This stage has allowed the comparison between typical defects in the injection moulding process and products (already commercialized and considered of high commercial and/or creative value) characterized by a similar morphology. For each defect some parameters were considered such as the possibility of intervention by the designer, the level and the type of this intervention. In conclusion, the research has investigated potential strategies for process innovation through the creative role of design, highlighting flaws and imperfections that can be recruited by the market, becoming a presumption for uniqueness on the inside of serial production.