Laser cutting machines are mesmerising to watch in operation. It is a computer-guided process – data is inputted and the machine runs its course – known as computer numerical control (CNC). One of the many advantages of CNC is the ability to produce extremely accurate parts to precise tolerances.

Acrylic – poly methyl methacrylate (PMMA) – is ideally suited to laser cutting, scoring and engraving, because the heat of the laser produces a gloss finish. The scored lines appear to glow, an affect known as 'edge glow'. This is caused by light picked up on the surface of the sheet and transmitted out through the edges. The scoring acts like an edge and fluoresces in the same way, accentuated by the yellow tint.

Image: This pattern was designed by Ansel in Illustrator and scored (etched) using a CO2 laser. It is an adaptation of a similar design he produced for a streetwear collection by Vexed Generation.

Polyethylene (PE) is an exceptional material. Not only is it used to make a wide range of commodity products, including plastic bags and drink cartons, it is used as a ballistic material by the US and UK military. It is suited to these applications because it has exceptional resistance to punching and tearing. Its properties are partly determined by its molecular weight.

In 1970s DSM developed Dyneema, which is classified as an ultra high density PE (UHDPE). As a drawn fibre or sheet it is up to 40% stronger than DuPont Kevlar and 15 times stronger than steel. As a result of its superior resistance to impact, laminated sheets up to 25 mm (1 in.) thick provide the protective lining for armoured military vehicles. Other high performance applications include parachute strings, ropes and bullet proof vests.

Image: PE milk cartons

As a designer, I am aware that it is important to strike a balance between inspirational materials and processes being developed in laboratories, and the fundamental materials and processes that make up the objects around us. Even so, many of the technologies now being used to produce consumer products, like computers and mobile phones, are becoming well-guarded secrets, giving brands their competitive edge.

My recently published book, Manufacturing Processes for Design Professionals, covers a wide range of innovative materials and manufacturing processes that are having an impact on the design industry. The plan for this blog is to build on the success of Mode of Production, an exhibition that I curated in London last September during London Design Festival.

I saw these composite plastic panels at the Surface Design Show in London this year. They are produced by Bencore, an Italian manufacturer, and demonstrate some of the most endearing qualities of plastic - they are bright, colourful and lustrous. Both the cylindrical core and tough outer sheets are polycarbonate (PC). An amorphous polymer (unorganised and non-crystalline molecular structure), PC has excellent clarity, is tough and resistant to impact. All of these qualities have contributed to the widespread application of PC in consumer products, furniture and the iconic Apple iMacs.

Other materials used by Bencore include styrene acrylonitrile (SAN), high impact polystyrene (HIPS) and polyethylene terephthalate modified with glycol (PETG), all of which have excellent optical properties. I've seen these panels used in trade fair stands, shops, interiors and furniture. They look great backlit. There are many more types of plastic and composite panel and some interesting structural ones too (suitable for floors and wall), which I will talk about another time.

Image: Bencore composite panels