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SECTION 3:implications of wider issues
3.1 what factors need to be considered while investigating design possibilities?
What do you care most about when buying a product?
probably the cost, right?
your considerations should be more like this:
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natural resource consumption?
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raw material gathering?
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social responsibility?
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legislation?
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environmental impact?
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can it be disassembled or repaired easily?
before launching into this topic it us useful to know you should have prior knowledge of:
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what can influence culture, lifestyle, industry and enterprise
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how materials, manufacturing processes and techniques can impact the environment
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the importance of sustainability
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how designing and making can be influenced by a range of initiatives and awarenesses
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how electricity is generated and stored
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renewabel and non-renewable energy sources
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maths and science applications in design & technology
Section 3 top
and this is why. your influence (as a designer) on product impact is huge and you need to look at a much wider range of considerations:
what are the stages of a products life that need considering?
raw material extraction
T
End of life
LCA
product use
material processing
part manufacture
assembly
T
T
T
T
Life cycle assessment
circular economy
linear economy ends here
T = transportation
at each stage of the lca for any product, it is incredibly important to explore the impact it is having, whether its for energy consumption and pollution, or deforestation and habitat destruction.
consider everything form powering the factory that builds the equipment that extracts the material, right through to the ability to recycle a products materials
the source and origin of materials; and the ecological and social footprint of materials
consider the device you are reading this on, where did the materials that went into its manufacture come from?
Social footprint - the impact we have on other people
Ecological footprint - the impact we have on the environment and natural resources
Carbon footprint - refers to the greenhouse gasses released by human activity and comes in 2 parts:
a primary footprint - direct emissions from burning fossil fuels
a secondary footprint - indirect emissions from the products we use
How big is your carbon footprint?
As a subject, one of the main considerations which will contribute to the various footprints, (along with choices of manufacturing), is the selection of materials, Their resourcing and origin.
Natural Materials - these come from plants, animals and the ground.
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Metals
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timbers
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natural fibres
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papers & boards
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leather
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biopolymers
Synthetic Materials - these come from chemical manipulation.
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synthetic polymers
each of the categories above have a wide variety of types within them, each having a different impact on the environment and its sustainability. More information to their impact can be found in the materials section but the main things to consider are:
Metals use an incredible amount of energy to source and recycle but they are completely recyclable. A very versatile material.
Timbers (hardwoods, softwoods and manmade boards) all have different considerations but come from sustainable sources. They cannot be recycled but can be repurposed.
Natural fibres can be easily sourced and regrown. huge amounts of water and energy are used to process them though.
Polymers can be synthetic or natural. Synthetic polymers are made from crude oil (a natural, non-renewable resource). not so good for the environment, however many polymers can be recycled.
Not only do the materials and method for manufacture need to be considered, but method of fuelling the process should be a factor too. The Depletion of natural energy sources is a huge global concern and needs to be considered by all.
The key non-renewable energy sources we have relied of for years are:
Gas
Coal
Oil
Renewable energy sources which are starting to provide more and more of our energy are:
Hydro-electric
Wind
Solar photovoltaic
Tidal Barrages
wave
geothermal
Biomass
Is there anyone encouraging us to change our ways?
> The EU Renewable Energy directive (red)
> Wood from controlled sources (fsc/ pefc)
> Other environmental targets
recycling
sustainable energy
air quality
wildlife protection
environmental excellence
Electronic waste reduction (WEEE)
Single use plastic reduction
renewable energy
3.2 what factors need to be considered when developing design solutions for manufacture?
Design for manufacturing -
they are not separate from each other
Planning for accuracy by testing and prototyping
Scales of production - how many are you making?
Design for repair and maintenance
Designing considering product life
DFMA - design for manufacture & assembly
this is all about making a product which is:
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the most affordable/ economical
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the most renewable
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the most efficiently manufactured
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the most easily repairable
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the most appropriately resourced
Some examples of considerations are:
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minimising the number of components/ parts used in the product
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standardising any parts or materials
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reducing the number of manufacturing processes needed
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creating/ using modular or symmetrical parts
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creating methods of efficient joining
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applying an appropriate surface finish for maximum durability
this needs to be done in conjunction with the 10 things of 'good design'
Who does this really well?
over the years ikea have developed hundreds of products, but more recently they have further developed their ease of assembly, including more use of standard components, modular assembly and symmetrical parts. This has allowed for easier manufacture/ assembly and easy upgrades of products when styles change, or bits get broken.
better for them, better for you, better for the environment
Everyone is a winner!
these same components (along with a few other) are used to assembly hundreds of different products, from book cases, to kitchen units and wardrobes.
ikea furniture is also flatpack which (despite the huge amounts of packaging), makes transportation much easier/ efficient!
How many are you going to make? - is the design suitable?
depending on how many of the same product you intend to manufacture, your methods might vary. A simple example of this is in your NEA - you may choose to manufacture part of it using 3D printing. This is great for a one off prototype but no good for the mass manufacture of the same part. an industrial alternative would be injection moulding - a process that is no good for one off manufacture.
things you might consider are:
One off
batch
Mass
continuous
J-i-t
lean
materials
fixings
joining methods
bought in components
number of parts
Looking at the bigger picture - keep the planet spinning.
quite simply, if you can repair it, you don't have to bin it. that's good for the planet right? So what makes something easier to repair then?
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temporary fixings - nuts/ bolts, screws etc (standardised components)
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materials free from surface finishes - these are hard to match
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having easy access to replacement parts - 'i need part 37'
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having multifunctional parts - something that is structural and functional
it works perfectly, but if that bit breaks, the whole product needs binning - yikes!
considering the wider impact of the product:
Has the length of the products life been considered?
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Built-in-obsolescence
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use of raw materials
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reduced replacement products sold
What else has been considered?
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cost
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manufacturing method
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Carbon footprint
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energy use (product manufacture)
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energy use (product use)
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material source
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Material choice
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recyclability
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hazardous waste
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maintenance
DFE
Design For Environment
LCA
Life cycle assessment
Why do we need to consider the wider impact of the product - your responsibility?
Have you ever considered any of the following?
how full are the landfills?
how many trees are left?
how much crude oil is left?
how much pollution is there?
how many species of animal are now extinct?
The answers to the questions above are everyone's responsibility, however as a designer and a manufacturer you have a huge potential to impact/ influence these answers.
One key thing to consider is DFMA (design for manufacture and assembly)
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design products that are easy to manufacture
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design products that are easy to assemble
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design products that are easy to repair
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design products that are easy to disassemble
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design products that are easy to recycle
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carefully consider material origin
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carefully consider the manufacturing process
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carefully consider the number of parts required
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keep the design as simple as possible
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consider surface finishes
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consider packaging
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consider transportation
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consider joining methods
consider energy use/ demand across all of these
aprox 70% of manufacturing costs are defined at the design stage
Quality & accuracy still matters too though!
Part of ensuring a product lasts is to ensure it works efficiently - something that can come down to the Quality and accuracy of how a product is made.
Can you reduce the number of parts by making them:
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symmetrical?
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multi-functional?
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minimal? (optimisation)
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bi-directional (can be used either way round)
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no surface finish (e.g. measurements need to be tested if a part is to have a layer of paint)
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standardised?
Does it matter how many you are making - scales of production?
making a one off prototype for a college project is one thing, you can use scraps, you don't have to transport anything directly, etc. your impact is minimal. However, consider the other end of the scale where you are mass producing products on an international level. what happens the? what is the impact?
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high energy use
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raw material extraction
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transportation impacts
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multi stage manufacturing
But you could ...
create modular designs to simplify assembly
reduce part numbers/ types
create one piece structures
use multifunctional components
use removable connectors
barcode/ e-tag components for easy identification
recycle waste
use recycled materials
How do you decide or predict how long a product is going to last and what can impact it?
System compatibility
products can quickly become out of date and need to be replaced but Some manufacturers allow for products to be updated - think about only being able to use the latest apps on the latest phone, and not on any previous models. No system updates? It wouldn't happen.
There are plenty of examples where older versions of things will not work with new technology, with the latest being cars. A new version (a greener version) of petrol is being introduced but can only be processed by newer cars - older cars will still need to run on the more expensive dirtier fuel.
Sticking with cars... my newest car doesn't have a CD player, let alone a tape player (do you even know what a tape is...?) The format of music has changed hugely over the last 30 years and each format requires a different device to play it. See the examples below and consider that now we stream music, we don't actually need any of them... evolution!
vinyl
compact disk
mini disk
8 track
cassette tape
mp3
Maintenance of 'the machinery'
If you're making something that moves, you want to make sure it keeps moving, safely and efficiently.
Take a bike for example. imagine racing down a hill and reaching for the brake, or wanting to change gear to get up the next hill...and it's not working for some reason. to ensure the devices for stopping the bike and changing its speed work properly, they need maintaining (looking after) on a regular basis - it's the same with all products that include moving parts.
For some products, there is a schedule of maintenance suggested to make sure the right parts are serviced at the right time. Take a car for example.
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You could also consider... When considering a product lifecycle, everything needs considering, even the care of the machine that makes the product - these need appropriately maintaining so they are working efficiently as they can - they contribute to the footprint of the product after all.
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When it all comes to an end...R.I.P my friend.
as a consumer you have probably thought about this more than you have as a designer or manufacturer, but what does happen is something breaks? What you do as a consumer is planned out by the designer - if you can fix it your self, have it fixed by a specialist or even having to throw the product away - that's all part of a well thought out plan.
Things like software updates, parts servicing, or even telephone
support - any ongoing help to keep the product going a little longer is best! (and promotes the brand/ company is a positive way - this is good for business)
EoL = end of life
linear economy = eol
Circular economy = product gets put back into the making of something new
Quite often, to retain your custom and ensure the company is doing their bit (for the environment), they will offer deals of part exchange - old for new. This is where you might receive a discount for upgrading a product and the company can appropriately recycle/ reuse your old version and keep you as a customer.
product
Think about the end first. then go back to the beginning
Consider your impact on the environment too.
No matter what you manufacture your product from, you will inevitably have an impact on the environment. Whether it's the sourcing of the material, the processing of the material, the transportation of the material or the disposal of the material - it all has an impact on the environment.
Metals.
eLECTROLYSIS IS USED TO TO EXTRACT MINED METALS FROM THEIR ORES. fOR EXAMPLE, WHEN STEEL IS MADE FROM IRON (THROUGH THE REMOVAL OF CARBON), CARBON DIOXIDE AND CARBON MONOXIDE ARE GENERATED AND RELEASED INTO THE ATMOSPHERE AS GREENHOUSE GASSES...aka, POLLUTION
Timbers, papers & boards
timber obviously comes from trees, created through the process of conversion. During this process trees are cut and then dried in a kiln (both using energy). Timber can be further processed into secondary materials such as boards - again using more energy.
Polymers.
By refining crude oil and creating paraffin, lubricating oil and petrol (monomers), we can further create polymers. This process uses huge amounts of energy, creates greenhouse gasses and pollutes. There are also numerous environmental concerns over transportation of crude oil... usually oil spills. The EOL for plastic based products must also be considered.
Cost implications.
Think about where products are made and who makes them. it is likely that they were manufactured where its cheapest to do so. Sometimes this is because of a location in terms of raw material, potential consumer or manufacturing labour costs.
The ultimate consideration is whether the final product is safe to use for it's intended purpose.
Good
fast
Cheap
poor quality
slow
expensive
Rare
economic issues & globalisation.
Take IKEA as an example of a world wide trading company - it has achieved globalisation! Things like the internet, electronic payment (including the developed use of cryptocurrencies), transportation links and trade agreements between countries have supported this.
Another contributor to this is the ability to be able to design in one country, manufacture components in various other countries and then assemble and package in yet another different country. The development of CAD/ CAM/ VR and AR have supported this.
Take note though, a company has to sell products which are highly desirable by millions of people around the world - not something that is easy to achieve. This is careful inclusive design but may change country to country.
Remember that things change though. A pandemic. Brexit. terms change, prices increase, demand can drop.
Optimisation.
It's not just about having the best idea, 'Everything' matters when it comes to being the best.
Natural fabrics
The main natural fabric used is cotton. Generally this is viewed as a positive material to use, especially in comparison to an alternative of polyester (both can be used to make clothing for example). However there are drawbacks. The growing of and processing of cotton uses huge amounts of water (as does the processing of wool, silk and leather).
The colouring of many natural materials can include the use of harmful chemicals too which can contaminate water supplies
Have you ever considered who made your clothes, furniture, phone or car? The man, woman or child who physically put it together? Have you thought about where they live, how they are treated or how much they are paid?
Fairtrade.
This is an initiative with a focus on ensuring better prices, safe and fair working conditions and fair terms for farmers. It also looks at ensuring the environment is cared for to promote future sustainability.
Ethical trade initiative (eti).
Similar to Fairtrade this an alliance of organisations which promotes and fights for workers' rights around the world. It helps with international trade ensuring poorer people are not disadvantaged.
Material sustainability
'The ability to maintain a certain level of material, for our generation and the generations to follow' - in terms of material, not running out and ensuring the impact of their use doesn't do unrepairable damage to the planet and environment.
So the big question is, what do you do? how do you contribute to a more sustainable existence, in terms of material use that is?
Material
Suitability
processing demands
Reclaimed
Recyclable
'replacability'
Origin
Optimisation is all about making the most efficient, 'optimised' product you can, considering materials, manufacturing processes, assembly methods, performance, size, weight, design features, sustainability, etc.
Optimisation can come from good old fashioned design development, iteratively editing a design until it is the best version in terms of everything in green above. Or, it can come CAD and the click of a button on a piece of software.
Optimisation types include structural optimisation, size optimisation and topology optimisation.
Structural optimisation = Finite element analysis (structural/ algorithms)
Size optimisation = development of product part sizes (shell, beam, cross section)
Topology optimisation = material layout (biomimicry enhanced)
the 6 r's
As a commonly used way for remembering some key considerations when it comes to making steps towards to reducing the impact on the environment, the 6R's give a good set of areas to start your focus.
Rethink:
Do you realise the worlds resources are limited and global warming is real?
> Do you, as a consumer really need to buy that product?
> Do you, as a designer or manufacturer really need to produce it?
Refuse:
You have a choice. You don't have to accept it! Refuse it! Actions create changes.
> you can refuse to buy the product with pointless packaging.
> Would someone refuse your product because its damaging to the environment? don't give them a reason.
Recycle:
This is an easy one for everyone to do. Put it in the recycle bin.
> Think about circular economy, design something that can be disassembled and recycled.
> Can you create something from recycled?
Repair:
Most things break at some point and need fixing. But how easy is it?
> Can you fix it? Should you be able to fix it?
> If you design a product, can it be fixed easily? You should design for repair and maintenance.
Reduce:
Reduce what? the energy used? transportation? Material waste? Packaging?
> Think design optimisation here.
Reuse:
use it again!
> can you use the product for something else once it comes to the Eol?
> Can the packaging be used for something instead of going straight in the bin (recycling bin obviously)
R's
SIX
Going greener
If you were to consider much of the above (and below), a key focus for wanting to do things in a more considered way is to reduce our carbon footprint and lessen the greenhouse effect.
Simply put, a reduction in the use of raw materials, fossil fuels and needless disposal, along with an increase in sustainable products, energy and transport would make the planet a greener place.
Eco materials.
No matter what you manufacture your product from, you will inevitably have an impact on the environment. Whether it's the sourcing of the material, the processing of the material, the transportation of the material or the disposal of the material - it all has an impact on the environment.
papers and boards
> Made from wood pulp = trees = renewable
> Can be manufactured from recycled material
> Can be recycled after use
> consider material origin
> Multi-purpose
glass
> Infinitely recyclable
> uses lots of energy to process
> Can be repurposed (multi use)
bamboo
> quick growing
> natural materials
> Versatile
(also great for creating oxygen (35% more than trees)
wood (reclaimed)
Re using timber and giving it a second life is a great way to save on new material use and material waste.
The use of reclaimed pallets its very popular right now
cork
> quick growing
> natural materials
> impermeable
> can be waterproofed
> Versatile
biopolymers
Made of material derived from sugar-cane fibre, corn starch or potato starch. a great alternative to polymer from crude oil processing.
fabrics (natural, not synthetic)
materials such as hemp (fast growing) and soy fabric (leftover tofu pulp) can be a great alternative to materials like nylon or acrylic.
Not to forget the obvious ones like cotton and wool (animal fibre) too.
Selecting materials which have a lesser impact on the environment is the right thing to do. Unfortunately there does need to be a balance between the required characteristics of a material and the functional ability of some of the eco-materials above. An alternative approach could be to look at using reclaimed materials:
upcycling
This is where you take an existing product, or the material from it, and recreate/ repurpose it. Like lots of areas of design, there are loads of examples of where this has been done really well, but there are also lots of examples where this hasn't.
Sourcing materials in only one aspect of the decision you should make when it comes to what to use. Other considerations include the transportation, processing and disposal of the materials. Consider:
> How much energy is used to transport the material? Where does it come from?
> How much energy is used to machine the material? What processes does it need to go through?
> What type of energy is used? Could it be renewable?
> What happens to the material at the products EOL? Recycled or other?
Consider the Greenhouse effect
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before you move on to the subsection below (which has a focus on the considerations for manufacture), consider that the info above, (despite discussing things about manufacture) is actually about the decisions made in the design process - getting this right is key to a lesser impact through manufacturing.
this next section is about manufacturing, not designing.
Optimum use of materials and components is fundamental in design and manufacturing- getting the most from your material choice should be a key focus and will include consideration of the following:
> material properties (mechanical, physical, electrical, aesthetic, machinable)
> cost (from source, processing and transporting)
> availability (what stock forms are available?)
> processing (the most efficient and environmentally friendly)
> environmental impact - environment on the product/ part (rain, wind, uv, etc.)
> Environmental impact - part on the environment (polluting)
> environmental - processing the part (energy used + pollution)
So, as a designer How do you know which material is going to be the most suitable? The answer is you might not, the manufacturer will probably help with that choice, however you need to be aware of potential/ possible materials and the following questions can help:
What does the product/ component do?
Where will it be used?
How will it be maintained?
what should it look like?
how will electrical or mechanical parts interact?
who will be using it?
how much will the final product cost?
how many are going to be made?
What manufacturing methods will be used?
What material properties are required?
How sustainable are the choices?
3.3 What factors need to be considered when manufacturing products?
Material properties:
Mechanical - strength, modulus
Physical - density, meting point
Electrical - conductivity, resistivity
Aesthetic - appearance, texture, colour
Machineability - ease of working, mouldability, etc
Product requirements:
Performance - reliability - size/ shape/ mass
cost - manufacturing - assembly - standards
regulations - intellectual property
sustainability
3.4 what factors need to be considered when distributing products to markets?
The distribution of products to market should be as effective and safe as possible, ensuring that:
> products are not damaged
> people and animals are not harmed
> the environment is not damaged
So, the question is, how do you get a product from the manufacturer to the consumer? This is known as the distribution channel and can include the use of shops, tv shopping or the internet. Think about if a consumer needs/ wants to see or try on the product before purchasing. Your options are:
Cost effective distribution:
Considering the structures above can alter the time it takes a product to get to a particular level of the channel. it may also impact the cost and consideration will be the amount of profit made at each stage.
Environmental issues and energy requirements:
If you manufacture and distribute products, using energy and creating pollution, you are obliged to follow some rules:
> reduce the amount of packaging you use
> reduce the amount of packaging that goes to landfill after product opening
> increase the amount of packaging that can be recycled or recovered
Social media and mobile technology (smm):
Global production and delivery:
Intellectual property:
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here
Manufacturer
Consumer
Manufacturer
Retailer
Consumer
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(£2)
(£3)
(£2)
(Direct distribution)
Manufacturer
Consumer
Manufacturer
Consumer
Wholesaler
Wholesaler
Retailer
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(£1)
(£3)
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(£2)
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(£3)
A Registered Design:
Ownership of a products appearance. To be registered a product must be:
> New & original
> Be unique
> Not resemble an existing design
They must be reviewed every 5 years
Trademark:
uSED TO IDENTIFY A BRAND OR DISTINGUISH A PRODUCT.
tHINK WORDS, NAMES, SONGS OR SYMBOLS
a tm MUST BE:
> UNIQUE & DISTINCTIVE
> fAIR AND ACCURATE
> mORALLY ACCEPTABLE
Copyright:
eXCLUSIVE RIGHTS OR PROTECTION OF ORIGINAL IDEAS OR INFORMATION.
cOPYRIGHT PROTECTION IS AUTOMATIC AND LASTS FOR 70 YEARS (25 FOR PHOTOS) - NO NEED TO REGISTER.
Design Rights:
tHIS PROTECTS THE CONFIGERATION OR SHAPE OF A PRODUCT AND PREVENT IT BEING COPIED.
tHEY STAY IN FORCE FOR 10 YEARS AFTER PRODUCT MARKETING, OR FOR 15 AFTER THE DESIGN CREATION - WHICH EVER IS FIRST. 2D ASPECTS ARE NOT PROTECTED BUT CAN BE REGISTERED SEPARATELY.
Patents:
tHE MOST COMMON and most protective form of ip PROTECTION.
Difficult to obtain but last 20 years.
Technical and functional aspects covered
For a patent to be considered the product must:
> be new
> include an inventive step
> be capable of being made
tm
r
c
3.5 how can skills and knowledge from other subject areas, including mathematics and science, inform decisions in design engineering & Product Design?
Don't be afraid to ask someone for help or advice. No one knows everything! Whether its advice from specialists in other areas or feedback from users and stakeholders, discussions with other people is going to be a key way to discover information about any project. Think about who you are and who you might want to speak to.
Designer
Scientist
Environmentalist
Material specialist
User
Distribution expert
Psychologist
field specialist
Collecting the correct research and information can be tricky. Sometimes its too easy to ask google something and take the first result - this is not appropriate research! You need to search for the information that is useful. This can be completed by conducting both primary and secondary research. Examples can include:
Primary Research
Questionnaires
Surveys
interviews
observations
Existing product research
Similar scenario reseach
Product sizes
Ergonomics
Data
* if you use the information someone else has gathered its known as secondary research.
3.6 what energy factors need to be considered when developing design solutions?
If you have ever experienced a power-cut, or been frustrated when your device is out of juice, then you will appreciate the importance of power. Some products use more power than others, and some behave differently if they don't receive the power required to make them function. think about the every day things you use that require power and where that power come from?
mobile phones
kitchen lights
electric car
airpods
computer
Mains electricity
+
Reliable
continuous high power
low cost
-
wired connection required
not portable
high voltage danger
Non-rechargeable batteries
+
readily available
simple solution
portable
-
expensive
environmental impact
runs out/ need changing
require access
Rechargeable batteries
+
Portable
no need to remove (if cabled)
LiPo batteries can be slim
can be replaced
-
Limited charge
limited lifecycle/ charges
requires charger
time to charge required
wind generator
+
free energy
clean energy
(smaller portable use available)
-
not consistent
servicing/ maintenance required
noisy
expensive set up
Eol impact
Solar photovoltaic
+
free energy
clean energy
long lasting
portable/ remote location use
-
low power output
inconsistent
Panels need cleaning
Don't forget about the other renewable energy types explored earlier:
In addition to these methods of providing energy, other forms such as liquid fuels (petrol and diesel)or compressed air can be used. A more futuristic approach to providing power is with Hydrogen fuel cells - something which is still being developed.
Currently, the method of creating electricity and heat from hydrogen and oxygen is not cheap or efficient enough to be used as a replacement for current energy types. It's also worth noting that the extraction of hydrogen uses lots of energy and unbalances the low environmental impact of using hydrogen fuel.
This is an add on to the info shared in the spec but it's a really useful way to remember some wider issues that need considering/ exploring with your product. Some are already discussed above but as part of TWERPS, here they are:
T - transportation - method, distance, journey, cost, availability...
W - Waste - how much, is it avoidable, what happens with it...
E - Energy - origin, renewability, storage...
R - Raw materials - location, renewability, who gathers it...
P - Pollution - extraction, processing, use and disposal/ recycling...
S - Socioeconomic issues - people, pay, safety and security...
Please note that when it comes to your NEA project, this website and the textbook only provide a starting place for materials research. There is a huge amount more of information available from data books, manufacturer's literature, the internet and material selection charts.
Time to test your knowledge. Click on the link below and enter the room ncbdtthree
log into memrise and then click below
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test your Section 3 key terms understanding here
Design Technology @ NCB
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