Eco-Design Case Studies

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Window Mounted Solar Light

author10 EDS 27 PRR 16

Foldable Hanger

author10 EDS 18 PRR 21

Bicycle Handlebar Grip

author10 EDS 28 PRR 7

Football Solar Light

author10 EDS 13 PRR 2

Spiral Adjustable Shade

author10 EDS 19 PRR 5

Polyhedron Adjustable Shade

author10 EDS 15 PRR 7


© 2015 MISMIR®

Parametric Model

Window Mounted Solar Light


author09 Ida_Kovaljova 12 comments Uploaded 12 July 15 PRR 16 Eco-Design Score - 27


This is a 3D printed Shade for the Window Mounted Solar Light. The idea is to transform the regular outdoor Solar Light into the indoor light source. The Solar Light consists of 3D manufactured shade, three discarded plastic suckers with broken hooks, and the discarded garden solar light with the broken pole.

INTRODUCTION

This Case Study was developed to illustrate several Eco-Design principles apart from the main one - use of renewable decentralized energy source:

• Recycling, reusing and repurposing, which refers to the discarded plastic suckers with broken hooks, and LED, switch, and other parts of the solar light, which usually is equipped with the plastic pole lacking rigidity, so it breaks quite often;

• Minimising amount and number of material required to manufacture and assembly the product, which refers to the push-fit assembly, where shade is playing the role of the fixture at the same time;

• No permanent joint solution is representing Design for Disassembly principle, as well as highly adaptable solution allowing quickly disassemble the product to substitute the batteries or any other part if needed.

PROBLEM STATEMENT

Various researchers argue, that energy consumption during the use phase of the products, which need power in order to function, is far greater comparing to the energy needed for their manufacturing. On the other hand, the products like wall mounted hooks with suckers, and garden solar lights are not durable, and the solution offering the second life option for their parts illustrates well the Sustainable design approach.

POTENTIAL SOLUTION

The 3D manufactured shade at the same time is playing the role of the fixture for the all the parts of the solar light. There are no screws needed to put together the Window Mounted Solar light, it is just a push-fit simple assembly. In order to achieve this kind of precision the discarded solar light and suckers were measured, so the 3D manufactured element openings are exactly the same size. In order to get the same results with the garden solar light MISMIR user has, the downloaded 3D printable file may need some alterations in terms of size. The Window Mounted Solar Light has a rechargeable accumulator, LED light, and the switch mechanism industrially manufactured and installed inside the solar light.

MANUFACTURING

The time needed for 3D manufacturing of the shade/fixture should take approximately 4-6 hours depending on the density chosen.

ASSEMBLY

The Window Mounted Solar Light needs to be assembled in the way the switch is positioned in front of the ornamental opening in the demi sphere of the 3d manufactured shade, so the switch is reachable for the finger. The fixtures for the suckers, the three cylinders, have grooves inside to secure the sucker legs in place. As an additional measure, to secure them in place it is recommended to sand a bit the sucker legs with a fine sanding paper so they have a rough surface. As the Window Mounted Solar Light weights so little, just 130g and is equipped with three suckers, when put on the window glass, it holds firmly. The suckers, on the other hand, are made of transparent plastic, so they do not interfere with the charging of the solar cell. The assembly may take 0,5 – 1 hour.

BILL OF MATERIALS

o 1 3D manufactured shade/fixture;

o 3 suckers;

o 1 outdoor solar light.

AFTERWORD

The Window Mounted Solar Light may prove to be physiologically comfortable solution. We all are used to the fact that during the daytime light comes indoors through the windows, but during the nigh time the artificial light sources are positioned everywhere in the room except the window. Probably, positioning the artificial light source where the natural daylight is usually coming from will be more comfortable for the people physiologically? This is a question is not to be answered by this Case Study as it requires deep comprehensive research.

Parametric Model

Foldable Hanger


author09 Ida_Kovaljova 5 comments Uploaded 13 July 15 PRR 21 Eco-Design Score - 18

INTRODUCTION

This Case Study was developed to illustrate several Eco-Design principles:

• Recycling, reusing and repurposing, which refers to the metal hook recuperated from the old broken plastic hanger;

• Minimising amount and number of material required to manufacture and assembly the product, which refers to the assembly consisting of only 3D manufactured plastic parts, no screws or nuts are need to assemble the Foldable Hanger;

• Use of geometrical solutions like ribbing reducing the amount of material and weight of the product, as well as increasing the overall plastic parts stiffness;

• No permanent joint solution representing Design for Disassembly principle, as well as highly adaptable solution allowing quickly disassemble the product to substitute any of its part if needed.

PROBLEM STATEMENT

Hangers we use on a daily basis are not very strong, the average life-span of the cheep hanger we usually get in the shop along with the clothes is 2-3 month, the wooden ones are much more durable, but in this Case Study we are talking about plastic hangers. If the plastic hangers equipped with metal hooks break, what's broken is usually their plastic parts, and what’s left is a metal hook. Collecting those hooks from the broken hangers in a 6 month you can get quite a collection, always depending on the amount of clothes you wear and the season (during winter we tend to wear more bulky heavy clothes than in the summer time).

POTENTIAL SOLUTION

The Foldable Hanger is easy to manufacture and assemble. It could be put into the folded position for storage until needed.

MANUFACTURING

Approximate manufacturing time for the Foldable Hanger is 8-10 hours depending on the density chosen, the assembly may take 30 minutes.

ASSEMBLY

The recycled metal hook should be inserted into the holes of the big blue parts number 1 and 2 to connect them.

Its tip should be bended. Then two halves of the cylinder number 3 and 4 should be positioned as shown on the drawing, and the big blue cylinder number 5 should be pushed over them and then turned to make pins enter into the grooves on the inner part of the cylinder 5 to secure the metal hook in place.

The Foldable Hanger is now assembled and is in the folded position. In order to put Foldable Hanger in the working position, the yellow part should be put over and fixed with two pins number 1 and 2.

Then three pins should be inserted into the holes to finish putting the Hanger into the working position.

TESTING

The Foldable Hanger design was tested using Solid Works Finite Element Analysis, which shows, that the hanger is able to hold up to 10 kg of clothes. The drawings show von Misses stress , and the deformation and displacement of the Foldable Hanger parts with the 10 kg of load. Other case studies could be potentially developed as a follow up. They could feature the hangers of different thicknesses with the labels imprinted on them to indicate the weight limit.

Sometimes we need a hanger just to put a freshly ironed shirt on, for this purpose there could be a Foldable Hanger with 3 kg weight limit, which, compared to the 10 kg Foldable Hanger, would need approximately 40% less material to 3D manufacture it. The label indicating the weight limit is clearly visible on the Foldable Hanger so the right hanger for the purpose could be easily chosen.

BILL OF MATERIALS

o Metal hook recycled from the old broken hanger;

3D manufactured parts:

o Hanger blue parts 1-5;

o Hanger yellow part with the weight limit label.

FOLDABLE HANGER DETAIL

Here you can see a close-up of the Foldable Hanger, which shows that the inner part of the hanger is made hollow to reduce the amount of material.

AFTERWORD

The 3D manufactured hanger may not prove to be more durable comparing to the traditional one, but it is certainly the better design solution in terms of upgradability and adaptability: if the one of the plastic part breaks, the user will recycle it using one of the devices like Ekocycle by Cubify, ProtoCycler, Filabot, Re-printer or another one able to recycle plastic waste; and then to re-manufacture the new part for the Foldable Hanger.

Parametric Model

Bicycle Handlebar Grip


author09 Ida_Kovaljova 7 comments Uploaded 15 July 15 PRR 7 Eco-Design Score - 28


This Case Study is illustrating the ultimate customization and personalization, which is only possible with personal scale 3D manufacturing. This Case Studyis an example of recycling, reusing and repurposing, which refers to the various gardening tools, which if equipped with such a handle, could become much more comfortable to perform the tasks were the significant force is needed.

INTRODUCTION

Bicycle Handlebar Grip Case Study is an example of ultimate customization, which is only possible for the product manufactured using Rapid Prototyping technique. The idea of this project is to create an imprint of both hands in order to create a “pefect grip”. In fact, this “perfect grip” could be used as a handle for the wide range of tools requiring significant forth to apply and, hence, the comfortable handle grip. The bicycle handlebar is just one of the many examples how the “perfect grip” handle could be successfully implemented.

PROBLEM STATEMENT

Many Do-It-Yourself or gardening tools require a lot of effort in order to perform a task. There are many budget tools on the market equipped with the standard wooden or plastic handles, which are quite comfortable when you just hold them, but become not so comfortable when you have to apply a forth or use them for a while. The handles often become slippery, start sliding in you hand and you even may end up with painful palm calluses.

POTENTIAL SOLUTION

In order to create the “perfect grip” for one’s hand, MISMIR user could create the imprint of both or just one hand using plasticine or papier mache using the following technique: place the pencil inside the amount of the mass approximately equivalent to the handle size, take into the hand and press firmly. Gently open the hand, and taking the imprint by the pencil, put the it between two objects, allowing the imprint to dry up without leaving any further marks on its surface.

When the plasticine/papier mache imprint is dried up, it should be placed vertically into the 3D scanner. There are self-adhesive dots to be positioned on the surface, those are quite helpful when you are trying to put together successfully scanned parts of the 3D scanned model.

The point cloud data obtained from the object, allows developing the parametric model of the handle grip using 3D modelling software of the user choice. The process of modelling going to take some time, depending on the level of skills of the particular user. The final 3D model of the handle should have the hole in the centre according to the size of the bar/handle it is designed for. It also should be divided into two parts and equipped with the holes for the screws to put it together around the bar/handle.

MANUFACTURING TIME

The time needed for rapid prototyping varies according to the 3D manufacturing device and the size of the product; approximately it should take 6-10 hours depending on the density chosen.

ASSEMBLY

The assembly instructions are indicated in the Exploded view: position the two halves of the Bicycle Handlebar Grip around the bicycle bar, insert the screw into the holes with the long screwdriver and fix them with washers and nuts.

The technical drawing of the product shows that the bar, in this case, has 10 mm radius. The final product looks as shown on the drawing.

BILL OF MATERIALS

o 4 screws, washers, and nuts;

2 3D manufactured halves of the handle.

Parametric Model

Football Solar Light




This Case Study was developed to illustrate several Eco-Design principles apart from the main one - use of renewable decentralized energy source:

• Recycling, reusing and repurposing, which refers to the LEDs, and other parts of the solar light, which usually is equipped with the plastic pole lacking rigidity, so it breaks quite often;

• Minimising amount and number of material required to manufacture and assembly the product, which refers to the hollow plastic hexagonal and pentagonal elements, which also have cut-out on the sides;

• Use of geometrical solutions like ribbing reducing the amount of material and weight of the product, as well as increasing the stiffness of pentagonal and hexagonal elements;

• No permanent joint solution representing Design for Disassembly principle, as well as highly adaptable solution allowing quickly disassemble the product to substitute the batteries or any other parts if needed.

INTRODUCTION

The Portable Football Solar light Case Study was developed to illustrate the implementation of Eco-Design principles: the Use of Renewable energy, Recycling and Repurposing.

PROBLEM STATEMENT

Various researchers argue, that energy consumption during the use phase of the products, which need power in order to function, is far greater comparing to the energy needed for their manufacturing.

POTENTIAL SOLUTION

The design solution allowing the Use of Renewable energy and doesn’t require centralized energy distribution, those two approaches are the most beneficial ones in terms of Sustainable development. The Portable Football Solar light consists of two identical halves , which can be put together and hold together due to the magnets installed into them. When put together, they impede the solar cells exposure to the light, which makes the LEDs to go on and emit the light. There is a switch installed inside the little hemispheric opening inside each half sphere, so the LEDs could be disabled when the ball is put together but the light is not needed. The sculptural nature of the object, its shape appreciated by football funs makes it desirable and complements the product function. Portable Football Solar light could be used indoors and outdoors.

For charging it should be exposed to the sunlight in the opened position, the best results could be achieved outdoors. When the accumulators are fully charged, the two halves of Portable Football Solar Light could be put together, and then brought back indoors to be used as an ambient light. If the intention is not to use the Football light immediately, then the LEDs should be switched off before putting two halves together, or they may simply be left apart.

MANUFACTURING

The time needed for 3D manufacturing of the pentagonal and hexagonal elements for each half of the Football vary according to the 3D manufacturing device and the size of the product; approximately it should take 25-35 hours depending on the density chosen. The assembly, soldering and adjustments should take approximately another 25-30 hours assuming the user is familiar with the soldering technique.

ASSEMBLY

The assembly process and the bill of materials are describing the one demi sphere of the Football Solar Light.

First of all, two hexagonal elements should be assembled with four screws and nuts.

Then, the pentagonal element with LED and accumulator already in place should be installed into the block of two pairs of hexagonal elements. It should be fixed with eight screws and nuts. Then, to cover the LED, the Plexiglas front pentagon should be installed, it is a simple push-fit assembly.

For this task the pentagonal element with the one solid face should be chosen, the solid face turn to the top. The photocells are already installed, so this is the rendering of the finished assembly of the block.

The bottom pentagonal element should be now installed in place. All the elements, the pentagonal and the hexagonal ones, have many openings at the back to connect wires inside.

BILL OF MATERIALS

In order to manufacture and assemble each half of the ball:

o 6 LEDs, 70 screws, 70 nuts;

o 15 photocells with 15 accumulators installed beneath them;

o Electric wires;

o 1 magnet;

o Soldering gun;

3D manufactured parts:

o 5 pentagonal elements with one solid face to install LEDs inside;

o 1 bottom/top pentagonal element to install LED inside it;

o 5 sets of pairs of the hexagonal elements;

o 6 pentagonal front faces cut out of Plexiglas.

Parametric Model

Spiral Adjustable Shade


author09 Ida_Kovaljova 12 comments Uploaded 12 July 15 PRR 5 Eco-Design Score - 19


This Case Study was developed to illustrate several Eco-Design principles apart from the main one – efficient energy use:

• Recycling, reusing and repurposing, which refers to the lamp with the broken shade, which usually gets discarded, as well as Yarn/Strings;

• Minimising amount and number of material required to manufacture and assembly the product, which refers to the push-fit assembly, where shade is just placed over the base and Yarn/String are playing the role of the fixture and the light adjustment at the same time.

• Use of sensors to minimise energy consumption.

• No permanent joints solution representing Design for Disassembly principle. This is also highly adaptable solution allowing quickly disassemble the product to substitute the light bulb, Yarn/String or any other part if needed.

INTRODUCTION

This is an Adjustable Intensity Shade. There is a Proximity Sensor installed inside the Spiral Adjustable Shade, which responds to the flattening of the Shade by reducing the Light Intensity. Pooling the strings downwards you can adjust the Spiral shade. Strings could be recycled from the old discarded knitted jumpers and so on.

PROBLEM STATEMENT

Many lamps are sold equipped with glass shades, so if the shade is broken or damaged to the point it cannot be used anymore, the lamp usually gets discarded.

POTENTIAL SOLUTION

There is an opportunity for designer to recycle the lamp base getting it a new shade with the proximity sensor installed above the light bulb. The light bulb, in this case, is limited to the energy saving or LED one, as they do not heat up as much as traditional incandescent light bulbs. In order to re-create the shade the base should be measured, so the cylinder of the new Shade fits the old lamp base, and the fixture from the old shade can be used for the new one to secure it in place. The STL file of the Spiral Adjustable Shade is available on the MISMIR website, it can be downloaded and scaled up or down to fit the lamp dimensions. Along with the STL file, there are technical drawing, the bill of materials, and the assembly instructions available. In some cases additional flat cylinder element could be added so the Shade fits the lamp base.

MANUFACTURING TIME

The time needed for 3D manufacturing of the Shade varies depending on the device and the size of the product. It should take approximately 8-10 hours depending on the density chosen. The assembly and adjustments should take another 6-10 hours including the Yarn or String weaving into the Shade rings.

ASSEMBLY

The Spiral Adjustable Shade, when 3D manufactured and installed in place along with the proximity sensor, also should be equipped with the Yarn weaved into the shade rings. The old knitted items like jumpers, sweaters, and scarfs could be used for this purpose. Colour plays an important role in this concept, so the Yarn colour should be chosen carefully depending on the colour scheme of the interior the lamp is placed in. The Yarn of different colours could be used.

After the Yarn is chosen according to its thickness and colour, it should be cut into pieces, and then tied in the knots to the upper rings of the Shade, and then weave them down through the rings of the Spiral Shade. In the bottom of the Shade they should be tied in the knot to the bottom ring element.

LIGHT INTENSITY ADJUSTMENT

The Spiral Shade intensity adjustment idea is based on the elasticity of the 3D manufactured items due to the nature of the ABS polymer used for rapid prototyping. The Spiral shape of the shade and the ABS polymer makes it easy to change the Shade height by pulling the strings downwards. When the top part of the Shade moves downwards the proximity sensor detects it and using the simple code and Arduino board sends the message to the light bulb to lower its intensity.

The proximity sensor plays the role of a dimmer in this project. Visually, however, the Shade also changes its appearance becoming lower, the lamp emits less light and consumes less energy. The Shade is transforming the energy consumption form the value, which cannot be perceived, to the clearly visible one. The difference of this concept from the traditional dimmer is that you can actually see not only the intensity of the light, but the changes in the shape of the Shade as well. When the eyes get used to the present level of the light intensity, the Shade is the only indication of the energy consumption.

BILL OF MATERIALS

o String/Yarn 3-4 m;

o 1 proximity sensor;

o 1 Arduino board.

3D manufactured parts:

o 1 spiral shade;

o 1 base with holes;

o 1 pin;

o 1 ring to fix the Strings/Yarn;

AFTERWORD

The peculiarity of this Case Study is that is never going to be two similar Shades. The way String/Yarn is weaved into the plastic rings of the shade, the choice of colour going to be unique. So go on, unleash your creativity!

Parametric Model

Polyhedron Adjustable Shade


author09 Ida_Kovaljova 12 comments Uploaded 12 July 15 PRR 7 Eco-Design Score - 15


This Case Study was developed to illustrate several Eco-Design principles apart from the main one – efficient energy use:

• Recycling, reusing and repurposing, which refers to the Yarn/Strings used to adjust the springs;

• Use of sensors to minimise energy consumption;

• No permanent joint solution representing Design for Disassembly principle, as well as highly adaptable solution allowing quickly disassemble the product to substitute the light bubl, Yarn/Strings or any other part if needed.

INTRODUCTION

This Case Study is similar to the Spiral Adjustable Shade one, the idea is to visualize the energy consumption; it differs by the geometrical shape which is changing in the process of light intensity adjustments. This shade is developed for the ceiling light, while the Spiral Shade fits the desktop lamp.

PROBLEM STATEMENT

The energy consumption is not easy to perceive, except when you are actually buying the new light bulb and can see its level of the energy consumption indicated on the label. The Polyhedron Shade is transforming the energy consumption form the value, which cannot be perceived, to the clearly visible one. Ceiling light is usually playing the role of an ambient light, so it is important to minimize the amount of energy needed for the task.

POTENTIAL SOLUTION

The size of the Polyhedron Adjustable shade is a direct analogy to the amount of the energy being consumed: when the shade expands, the light intensity is at its maximum, when the shade shrinks, the light is dimmed off. The difference of this concept from the traditional dimmer is that you can actually see not only the intensity of the light, but the changes in the shape of the Polyhedron Shade as well. When the eyes get used to the present level of the light intensity, the Shade is the only indication of the level of energy consumption.

LIGHT INTENSITY ADJUSTMENT

The Polyhedron Shade intensity adjustment idea is based on the geometry of the polyhedron, that sixrectangular pyramids fixed to the base sphere with telescopic tubes can push and pull eight triangular pyramids in order to make the whole body expand or retract. The bottom telescopic tube when pulled down make the six springs contract and makes the Shade smaller. When it happens, the proximity sensor detects it, and using the simple code and Arduino board sends the message to the light bulb to lower its intensity. So the proximity sensor plays the role of a dimmer. Visually, however, the Shade also changes its appearance, the shade becomes smaller; the lamp emits less light and consumes less energy. The STL file of the Polyhedron Adjustable Shade is available on the MISMIR website, it could be downloaded along with the bill of materials, and the assembly instructions.

The red telescopic tube 1 in the bottom is responsible for the size of the shade: when this part is down, the springs in the other 6 tubes are contracted and the shade is smaller; when the small pin 2 is removed and the red telescopic tube is up, the shade is expanded.

The proximity sensor detects the changes and sends information to the Arduino board, which adjusts the light intensity.

MANUFACTURING

The time needed to manufacture the Shade varies according to the 3D printer and the size of the product. Approximately, it should take about 25-30 hours depending on the density chosen. There are 6 springs installed into telescopic tubes; the springs are not 3D manufactured, they along with the poximity sensor, installed into the slot 1, Arduino board installed into the slot 2 and wires should be acquired at the electronics specialist like, for example, maplin.co.uk, sparkfun.com.

ASSEMBLY

The strings should be attached to the far end of the springs. The positioning of the springs and strings inside the structure is shown on the drawing.

The assembly and adjustments should take approximately 16-20 hours including the assembly of the telescopic tubes, springs and strings. The proximity sensor is installed aside from the light bulb, and the Arduino board is connected to the light bulb and the proximity sensor. The light bulb, in this case, is limited to the energy saving or LED one, as they do not heat up as much as traditional incandescent light bulbs.

BILL OF MATERIALS

o 6 springs and strings;

o 1 proximity sensor;

o 1 Arduino board.

3D manufactured parts:

o 8 triangular ones;

o 6 rectangular ones;

o 1 fixture with 6 telescopic tubes equipped with springs and strings;

o 1 telescopic tube in the bottom to adjust light intensity;