1. Strategies for Green Design

2. Design for Manufacture Definition: Design for manufacture (DfM) is when designers design specifically for optimum use of existing manufacturing capability.

3. Design for Manufacture DfM can be a dominating constraint on the design brief and can be conveniently split into: Design for materials Design for process Design for assembly

4. Design for Materials Definition: Designing in relation to materials during processing Design for Process Definition: Designing to enable the product to be manufactured using a specific manufacturing process, for example, injection moulding.

5. Design for Assembly Definition: Designing taking account of assembly at various levels, for example, component to component, components into sub- assemblies and sub-assemblies into complete products.

6. Strategies for DfM There are many strategies that designers can deploy to design for manufacture: Minimise the number of components Use standard components Design components that are multi-functional or for multi-use Design parts for ease of fabrication Minimise handling Use standard sub-assemblies

7. Strategies for DfM In groups, no larger than 4, discuss three strategies that designers could deploy for DfM and give examples where this has been used. Minimise the number of components Use standard components Design components that are multi-functional or for multi-use Design parts for ease of fabrication Minimise handling Use standard sub-assemblies

8. The designers role in DfM The designer can modify the environmental impact of the production, use and disposal of their product through careful consideration at the design stage.

9. A formula for change The four Rs of environmental development 1.Reuse 2.Repair 3.Reconditioning 4.Recycling

10. Reuse Definition: Reuse of a product in the same context or in a different context. For example: Refilling toner cartridges for photocopies or ink cartridges for printers Designing computers so that the CPU can be easily upgraded Using ice-cream containers as flower pots

11. Repair Definition: The construction or renewal of any part of an existing structure or device. For example: Circuit boards on a PC, laptop or mobile phone Watch or clock repair

12. Reconditioning Definition: Rebuilding a product so that it is in an “as new” condition, and is generally used in the context of car engines and tyres. For example: Engine parts or tyres on a car Vacuum cleaners

13. Recycling Definition: Recycling refers to using the materials from obsolete products to create other products. For example: Diaries and containers made using recycled paper.

14. Resource utilization Reuse, repair, reconditioning and recycling contribute to the optimization of resource utilization. By following the 4 Rs we will not need to consume as much non-renewable resources. We will have increased efficient use of materials. We will minimize damage or pollution from materials on landfill sites.

15. Strategies for the 4 Rs Reuse, repair and recycling can and has been applied to the design of products. Disposable cameras are recycled to be reused. Car tyres can be remoulded to improve the tread or can be recycled to produce new products, such as this mouse mat. Vacuum cleaners can be reconditioned to improve their performance.

16. Packaging It is, perhaps, in the area of packaging that we can produce the biggest reduction in material and energy consumption without affecting end-use performance or quality.

18. Reuse and Refill

19. Resource conservation may take the form of the reuse or refilling of containers, thus extending their functional lifetime. After minimising the use of resources in the first place, this route appears most environmentally attractive. However, the process of reusing and refilling has an environmental cost too, which must be considered. The energy cost of collecting and cleaning containers should not outweigh the energy value of manufacturing them in the first place, and packs may have to be reused many times before the initial investment in energy is recouped, so durability will be important. Containers also have to be designed so that they can be cleaned easily.

20. There are a variety of ways in which a refillable system can work. The container can be returned to the manufacturer for refilling; the user can take the container to a refill point; the user can purchase a refill pack from which a more durable container can be refilled. Whether any of these approaches is appropriate and beneficial will depend on the manufacturing and distribution systems involved and, of course, he nature of the product itself.

21. A self dispensing milk refill machine, used throughout the Tengelmann supermarket chain in Germany since 1988. Glass and recyclable plastic bottles are purchased from the store and filled with milk from the machine. When emptied, they are cleaned and brought back for refilling by the customer with no limit to the number of times they can be used. In Munich alone, the system resulted in the saving of 3700 tonnes of packaging waste per year.

22. Recyclable materials Most materials can be recycled, some are easier to recycle than others. Three materials which are easy and economical to recycle are: Thermoplastics Metals Glass

23. Recycling thermoplastics Thermoplastic is a type of plastic which softens under heat and can be re-softened many times. There is a "cascade" effect in the recycling of plastics: high ‑ performance plastics, after recycling, cannot be used for their original application. After several passages through the recycling loop, applications will be limited to very basic products, such as park benches or fence posts. This means that uses have to be found for recycled plastics in order to stimulate the development of a recycling infrastructure.

24. Some types of plastic can be reused several times. For example, soft drinks bottles can be used as raw material for the manufacture of detergent bottles. Extending the life of plastic makes better use of a valuable resource, but the collection and separation of plastic waste demands an effective waste management infrastructure.

25. This is true particularly if different types of plastic are recycled together, as may be inevitable with reclamation from household waste. The resultant material is unlike any virgin material, but may have interesting properties in its own right. Increasingly, designers will be faced with the challenge of finding significant uses for recycled plastics. 02, a group of European designers, have produced a range of experimental products from fragmented, pressed plastic obtained from a collection of bottles, plastic bags, old toys and packaging materials. Pure recycled material, for example from PET bottles, is likely to become a mainstream ingredient of packaging material, just as recycled paper is.

26. Recycling metal Two sorts of metal may be recycled or reused: products at the end of their life (called old scrap) and waste material such as rejects, swarf and offcuts from the manufacturing process (called new scrap). The diagram illustrates the distinction between old and new scrap in the context of aluminium drinks cans.

27. Recycling metal Aluminium Aluminium is produced from bauxite, a clay-like ore that is rich in aluminium compounds. The aluminium is only found as a compound called alumina, which is a hard material consisting of aluminium combined with oxygen. This alumina has to be stripped of its oxygen in order to free the aluminium. The alumina is dissolved in a molten salt at a reduction plant and a powerful electric current is run though the liquid to separate the aluminium from the oxygen. This process uses large quantities of energy.

28. Recycling metal Aluminium Recycling aluminium requires only 5% of the energy and produces only 5% of the CO2 emissions as compared with primary production and reduces the waste going to landfill. Aluminium can be recycled indefinitely, as reprocessing does not damage its structure. Aluminium is also the most cost-effective material to recycle. FACT: A recycled aluminium can saves enough energy to run a television for three hours

29. Recycling metal Steel Steel is also mined from an ore. Iron ore is plentiful but it too is usually combined with oxygen or sometimes carbon or sulphur. The iron ore is stripped in a blast furnace to reduce it to pig iron that can then be used in steel production. FACT: Each household uses approximately 600 steel cans per year.

30. Recycling metal Other metals Although present in smaller quantities - all metals including nickel, copper, silver, gold, lead, brass and more, can be recycled. Given their recognised value a smaller quantity of these metals are in circulation however with reliance on these metals by specific industries eg electronics their presence is often neglected when householders dispose of items.

31. Recycling glass Glass offers almost identical performance and appearance characteristics after recycling, and is therefore already used extensively in recycled form as a standard raw material.

32. Recycling glass 5 Reasons to Recycle T:\Tech-art\Design Technology\IB\Year 12 2007- 8\Core\Green Design\5Reasons.pdf Amazing Facts about Glass Recycling: T:\Tech-art\Design Technology\IB\Year 12 2007- 8\Core\Green Design\British Glass - Amazing Facts.htm The Glass recycling Cycle www.britglass.org.uk/Education/RecyclingCycle www.britglass.org.uk/Education/RecyclingCycle

33. Disassembling products for recycling Most products comprise several different materials, which need to be separated before the product can be recycled. Example: A washing machine may have a metal shell with a plastic top, or a refrigerator has a metal shell with a plastic interior and handle.

34. Composite materials A composite is a mixture composed of two or more substances (materials) with one substance acting as the matrix or glue. An example of a composite material is fiberglass. Fiberglass is made using glass fibers and resin.

35. Drum table made from grindings from the tyre re-treading industry Drawer pedestal made from metal and recycled plastic. The drawer fronts contain 74 milk jugs Chair using black extruded, recycled post-consumer HDPE and green recyclate made from stretch wrap film

36. Designers should always consider whether a recycled material might perform the function just as well as a virgin material, and should. request a good selection of recycled materials from suppliers. There is little point in selecting a material which can be recycled if no mechanism exists, or is likely to exist, to enable it to be recycled, or if the product has not been designed with easy recycling in mind. Economic Issues of Recycling

37. Materials which are difficult to recycle may have other benefits, such as greater energy efficiency. Example: The replacement in the automotive industry of easily recyclable steel and iron by hard ‑ to ‑ recycle plastics helped improve fuel consumption because of the savings that could be achieved in the weight of the car. However, the inclusion of higher quantities of plastic made it more difficult for scrap merchants to retrieve the metal parts, thus increasing their costs and diminishing the value of the metals recycling process. Efforts to develop plastic components which are easy to dismantle and separate, and which can be recycled themselves, may reduce this problem.

38. Consumer Issues Designers also have a role in improving the products and systems that are now becoming available to help the public collect their waste in a way that best assists recycling. The need to identify, separate and store different kinds of waste is presenting entirely new problems for designers of rubbish bins, kitchens and supermarkets alike.

39. Design for Disassembly Definition: Designing a product so that when it becomes obsolete it can easily and economically be taken apart, the components reused or repaired, and the materials recycled.

40. Design for Disassembly Design for disassembly is one aspect of design for materials and will facilitate recycling of products on disposal. This car has been designed for disassembly.

41. Strategies for Design for Disassembly Strategy 1: Designing components made from one material. Strategy 2: Using thermoplastic adhesives that lose their properties when reheated. Strategy 3: Designing snap fittings instead of welding and gluing. Can you think of anymore???