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Timothy Harris Sustainable Design DSID 130
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Timothy HarrisSustainable Design DSID 130
Timothy Harris DSID 130Timothy Harris DSID 130
Mindful Design Problem Statement
Sustainable Design doesn’t have to do with simply being green. It doesn’t have to do with off-setting a carbon foot print, or saving the trees, or harnessing whatever flavor of renewable energy is in demand. It has to do with reducing the demands of our product on the earth while still meeting the demands of the consumer.
In regards to this course, what is necessary is determined by what is currently demanded. A consumer electronic product valuing between $50-150 is chosen, deconstructed, and evaluated for its impact based on a planet-mindful system of metrics designed by Okala. Using this metric, design a product with equal or greater capabilities while reducing its overall impact by 50%.
Timothy Harris DSID 130Timothy Harris DSID 130
The Product
The product chosen was a rechargeable bicycle headlight, the Metro 360 by Cygolite. It features an internal 18650 cell that charges via an included USB cable. The lamp can cycle through various modes of brightness or fl ash interval depending on cycling conditions. Interestingly enough the company suggests that the product not be used for off -bicycle purposes. All attempts to contact the company for information regarding the fl ashlight were unreturned.
The product was disassembled and laid out to visualize the components inside.Component List:1. Large Clasp Collar2. Clasp Hinge Collar3. Clasp Nut w/ Insert4. Clasp Eye Bolt5. Clasp Nut6. Main Body Screws7. Main Button Dust Cover8. Battery PCB9. Battery Washer10. Battery 11.Battery12. Battery Heat Shrink13. Upper and Lower Retainer Body14. Upper and lower Retainer Grip15. Main Body Forward Half16. Lens17. Main Body Heatsink Gasket18. Heatsink Body19. LED screws20. Heatsink Plate21. Heatsink Screws22. Battery Retainer23. Main Body Back Half24. Battery Heat Shrink (more of it)25. Slide Retainer Clip26. Slide Retainer Screw27. Retainer Washer28. Slide Hex Nut29. USB port Dust Cover 30. USB charging cable31. LED32. Battery Leads with Coupler33. LED PCB34. Zip Tie35. Twist Tie36. Battery Electrical Tape37. Battery Info Sticker38. Red Paper Battery Insulator39. Battery PCB insulator40. Battery Foam Sticker41. Battery White Sticker42. “360” Sticker43. Paper Packaging44. USB Plastic Bag45. Exterior Bag
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Timothy Harris DSID 130
Research LCATimHarris-RechargableBicycleFlashlightNotes-
Partsaremountedonpaper Productsays"engineeredandAssembledintheUSA."Phonecallconfirmedplaceofassembly,butnotmanufacture.Transportiscaluclatedfromfacilitytothehome(389mi),aswellascoasttocoast(2680mi).
Part# PartName Category Amount Unit Pounds Miles OKFP /unit OIP PartOPITotals
Product
1 LargeClaspCollar Material Stainless 1.12 grams 0.002464 N/A 13 perlb 0.032032Process StainlessSheetRolling 1.12 grams 0.002464 N/A 1.2 perlb 0.0029568
EndOfLife Landfill 1.12 grams 0.002464 N/A 0.51 perlb 0.00125664Transport Truck,16t 1.12 grams 0.002464 389 0.31 perton-mile 0.000148567Transport Truck,16t 1.12 grams 0.002464 2680 0.31 perton-mile 0.003929684
0.0403236912 ClaspEyeBolt Material Stainless 4.3 grams 0.00946 N/A 13 perlb 0.12298
Process SteelColdForging 4.3 grams 0.00946 N/A 0.56 perlb 0.0052976EndOfLife Landfill 4.3 grams 0.00946 N/A 0.51 perlb 0.0048246Transport Truck,16t 4.3 grams 0.00946 389 0.31 perton-mile 0.000570391Transport Truck,16t 4.3 grams 0.00946 2680 0.31 perton-mile 0.003929684
0.1376022753 ClaspNut Material StainlessandNylon 2.5 grams 0.0055 N/A 3.5 perlb 0.01925
Process Injection 2.5 grams 0.0055 N/A 0.72 perlb 0.00396EndOfLife Landfill 2.5 grams 0.0055 N/A 0.51 perlb 0.002805Transport Truck,16t 2.5 grams 0.0055 389 0.31 perton-mile 0.000331623Transport Truck,16t 2.5 grams 0.0055 2680 0.31 perton-mile 0.0022847
0.0286313234 ClaspNutw/Insert Material Aluminum 0.2 grams 0.00044 N/A 13 perlb 0.00572
Process ALMetalWorking 0.2 grams 0.00044 N/A 2.8 perlb 0.001232EndOfLife Landfill 0.2 grams 0.00044 N/A 0.39 perlb 0.0001716Transport Truck,16t 0.2 grams 0.00044 389 perton-mile 0Transport Truck,16t 0.2 grams 0.00044 2680 0.31 perton-mile 0.000182776
0.0073063765 ClaspHingeCollar Material Stainless 0.55 grams 0.00121 N/A 13 perlb 0.01573
Process StainlessSheetRolling 0.55 grams 0.00121 N/A 1.2 perlb 0.001452EndOfLife Landfill 0.55 grams 0.00121 N/A 0.51 perlb 0.0006171Transport Truck,16t 0.55 grams 0.00121 389 0.31 perton-mile 7.2957E-05Transport Truck,16t grams 0 2680 0.31 perton-mile 0
0.0178720576 SlideRetainerClip Material ABS 4.51 grams 0.009922 N/A 2.4 perlb 0.0238128
Process Injection 4.51 grams 0.009922 N/A 0.72 perlb 0.00714384EndOfLife Landfill 4.51 grams 0.009922 N/A 0.35 perlb 0.0034727Transport Truck,16t 4.51 grams 0.009922 389 0.31 perton-mile 0.000598247Transport Truck,16t 4.51 grams 0.009922 2680 0.31 perton-mile 0.004121599
0.0391491867 RetainerWasher Material Nylon 0.07 grams 0.000154 N/A 3.5 perlb 0.000539
Process Calendaring 0.07 grams 0.000154 N/A 0.21 perlb 0.00003234EndOfLife Landfill 0.07 grams 0.000154 N/A 0.6 perlb 0.0000924Transport Truck,16t 0.07 grams 0.000154 389 0.31 perton-mile 9.28543E-06Transport Truck,16t 0.07 grams 0.000154 2680 0.31 perton-mile 6.39716E-05
0.0007369978 SlideHexLockNut(nylon) Material StainlessandNylon 0.44 grams 0.000968 N/A 13 perlb 0.012584
Process SteelColdForging 0.44 grams 0.000968 N/A 0.56 perlb 0.00054208EndOfLife Landfill 0.44 grams 0.000968 N/A 0.51 perlb 0.00049368Transport Truck,16t 0.44 grams 0.000968 389 0.31 perton-mile 5.83656E-05Transport Truck,16t 0.44 grams 0.000968 2680 0.31 perton-mile 0.000402107
0.0140802339 RubberGripUpper Material Vinyl 1.7 grams 0.00374 N/A 13 perlb 0.04862
Process Injection 1.7 grams 0.00374 N/A 0.72 perlb 0.0026928EndOfLife Landfill 1.7 grams 0.00374 N/A 0.39 perlb 0.0014586Transport Truck,16t 1.7 grams 0.00374 389 0.31 perton-mile 0.000225503Transport Truck,16t 1.7 grams 0.00374 2680 0.31 perton-mile 0.001553596
0.05455049910 RetainerGripLower Material Vinyl 1.15 grams 0.00253 N/A 13 perlb 0.03289
Process Injection 1.15 grams 0.00253 N/A 0.72 perlb 0.0018216EndOfLife Landfill 1.15 grams 0.00253 N/A 0.39 perlb 0.0009867Transport Truck,16t 1.15 grams 0.00253 389 0.31 perton-mile 0.000152546Transport Truck,16t 1.15 grams 0.00253 2680 0.31 perton-mile 0.001050962
0.03690180811 RetauberScrew Material Stainless 0.81 grams 0.001782 N/A 13 perlb 0.023166
Process SteelColdForging 0.81 grams 0.001782 N/A 0.56 perlb 0.00099792EndOfLife Landfill 0.81 grams 0.001782 N/A 0.39 perlb 0.00069498Transport Truck,16t 0.81 grams 0.001782 389 0.31 perton-mile 0.000107446Transport Truck,16t 0.81 grams 0.001782 2680 0.31 perton-mile 0.000740243
0.02570658812 RetainerBodyUpper Material ABS 7.85 grams 0.01727 N/A 2.4 perlb 0.041448
Process Injection 7.85 grams 0.01727 N/A 0.72 perlb 0.0124344EndOfLife Landfill 7.85 grams 0.01727 N/A 0.35 perlb 0.0060445Transport Truck,16t 7.85 grams 0.01727 389 0.31 perton-mile 0.001041295Transport Truck,16t 7.85 grams 0.01727 2680 0.31 perton-mile 0.007173958
0.06814215313 RetainerBodyLower Material ABS 6.67 grams 0.014674 N/A 2.4 perlb 0.0352176
Process Injection 6.67 grams 0.014674 N/A 0.72 perlb 0.01056528EndOfLife Landfill 6.67 grams 0.014674 N/A 0.35 perlb 0.0051359Transport Truck,16t 6.67 grams 0.014674 389 0.31 perton-mile 0.000884769Transport Truck,16t 6.67 grams 0.014674 2680 0.31 perton-mile 0.00609558
0.05789912814 MainBodyDustCover Material Silicone 0.61 grams 0.001342 N/A 1.7 perlb 0.0022814
Process Injection 0.61 grams 0.001342 N/A 0.72 perlb 0.00096624EndOfLife Landfill(Elastomer) 0.61 grams 0.001342 N/A 0.39 perlb 0.00052338Transport Truck,16t 0.61 grams 0.001342 389 0.31 perton-mile 8.09159E-05
Transport Truck,16t 0.61 grams 0.001342 2680 0.31 perton-mile 0.0005574670.004409403
15 MainBodyButtonCover Material Silicone 0.84 grams 0.001848 N/A 1.7 perlb 0.0031416Process Injection 0.84 grams 0.001848 N/A 0.72 perlb 0.00133056
EndOfLife Landfill 0.84 grams 0.001848 N/A 0.39 perlb 0.00072072Transport Truck,16t 0.84 grams 0.001848 389 0.31 perton-mile 0.000111425Transport Truck,16t 0.84 grams 0.001848 2680 0.31 perton-mile 0.000767659
0.00607196416 MainBodyScrew Material Stainlessx3(.32factored) 0.96 grams 0.002112 N/A 13 perlb 0.027456
Process SteelColdForging 0.96 grams 0.002112 N/A 0.56 perlb 0.00118272EndOfLife Landfill 0.96 grams 0.002112 N/A 0.51 perlb 0.00107712Transport Truck,16t 0.96 grams 0.002112 389 0.31 perton-mile 0.000127343Transport Truck,16t 0.96 grams 0.002112 2680 0.31 perton-mile 0.000877325
0.03072050817 MainBodyHeatsinkGasket Material Silicone 0.33 grams 0.000726 N/A 1.7 perlb 0.0012342
Process Injection 0.33 grams 0.000726 N/A 0.72 perlb 0.00052272EndOfLife Landfill 0.33 grams 0.000726 N/A 0.39 perlb 0.00028314Transport Truck,16t 0.33 grams 0.000726 389 0.31 perton-mile 4.37742E-05Transport Truck,16t 0.33 grams 0.000726 2680 0.31 perton-mile 0.00030158
0.00238541518 HeatsinkScrew Material Stainlessx2(.2factored) 0.4 grams 0.00088 N/A 13 perlb 0.01144
Process SteelColdForging 0.4 grams 0.00088 N/A 0.56 perlb 0.0004928EndOfLife Landfill 0.4 grams 0.00088 N/A 0.51 perlb 0.0004488Transport Truck,16t 0.4 grams 0.00088 389 0.31 perton-mile 5.30596E-05Transport Truck,16t 0.4 grams 0.00088 2680 0.31 perton-mile 0.000365552
0.01280021219 "360"MylarSticker Material PET 0.001 grams 0.0000022 N/A 1.8 perlb 0.00000396
Process Calendaring 0.001 grams 0.0000022 N/A 0.21 perlb 0.000000462EndOfLife Landfill 0.001 grams 0.0000022 N/A 0.37 perlb 0.000000814Transport Truck,16t 0.001 grams 0.0000022 389 0.31 perton-mile 1.32649E-07Transport Truck,16t 0.001 grams 0.0000022 2680 0.31 perton-mile 9.1388E-07
6.28253E-0620 MainBodyForwardHalf Material ABS 10.23 grams 0.022506 N/A 2.4 perlb 0.0540144
Process Injection 10.23 grams 0.022506 N/A 0.72 perlb 0.01620432EndOfLife Landfill 10.23 grams 0.022506 N/A 0.35 perlb 0.0078771Transport Truck,16t 10.23 grams 0.022506 389 0.31 perton-mile 0.001356999Transport Truck,16t 10.23 grams 0.022506 2680 0.31 perton-mile 0.009348992
0.08880181221 MainBodyBackHalf Material ABS 21.11 grams 0.046442 N/A 2.4 perlb 0.1114608
Process Injection 21.11 grams 0.046442 N/A 0.72 perlb 0.03343824EndOfLife Landfill 21.11 grams 0.046442 N/A 0.35 perlb 0.0162547Transport Truck,16t 21.11 grams 0.046442 389 0.31 perton-mile 0.00280022Transport Truck,16t 21.11 grams 0.046442 2680 0.31 perton-mile 0.019292007
0.18324596722 Lens Material PC 2.56 grams 0.005632 N/A 3.7 perlb 0.0208384
Process Injection 2.56 grams 0.005632 N/A 0.72 perlb 0.00405504EndOfLife Landfill 2.56 grams 0.005632 N/A 0.61 perlb 0.00343552Transport Truck,16t 2.56 grams 0.005632 389 0.31 perton-mile 0.000339581Transport Truck,16t 2.56 grams 0.005632 2680 0.31 perton-mile 0.002339533
0.03100807423 LensGasket Material Silicone 0.92 grams 0.002024 N/A 1.7 perlb 0.0034408
Process Injection 0.92 grams 0.002024 N/A 0.72 perlb 0.00145728EndOfLife Landfill 0.92 grams 0.002024 N/A 0.39 perlb 0.00078936Transport Truck,16t 0.92 grams 0.002024 389 0.31 perton-mile 0.000122037Transport Truck,16t 0.92 grams 0.002024 2680 0.31 perton-mile 0.00084077
0.00665024724 MainHeatsink Material Aluminum 13.46 grams 0.029612 N/A 13 perlb 0.384956
Process DieCast(AluminuimMetalWorking) 13.46 grams 0.029612 N/A 2.8 perlb 0.0829136EndOfLife Landfill 13.46 grams 0.029612 N/A 0.39 perlb 0.01154868Transport Truck,16t 13.46 grams 0.029612 389 0.31 perton-mile 0.001785456Transport Truck,16t 13.46 grams 0.029612 2680 0.31 perton-mile 0.012300825
0.4935045625 HeatsinkPlate Material Aluminum 3.22 grams 0.007084 N/A 13 perlb 0.092092
Process AluminumMetalWorking(stamped) 3.22 grams 0.007084 N/A 2.8 perlb 0.0198352EndOfLife Landfill 3.22 grams 0.007084 N/A 0.39 perlb 0.00276276Transport Truck,16t 3.22 grams 0.007084 389 0.31 perton-mile 0.00042713Transport Truck,16t 3.22 grams 0.007084 2680 0.31 perton-mile 0.002942694
0.11805978326 BatteryRetainer Material ABS 2.62 grams 0.005764 N/A 2.4 perlb 0.0138336
Process Injection 2.62 grams 0.005764 N/A 0.72 perlb 0.00415008EndOfLife Landfill 2.62 grams 0.005764 N/A 0.35 perlb 0.0020174Transport Truck,16t 2.62 grams 0.005764 389 0.31 perton-mile 0.00034754Transport Truck,16t 2.62 grams 0.005764 2680 0.31 perton-mile 0.002394366
0.02274298627 LED Material LED 1.65 grams 0.00363 N/A 160 perlb 0.5808
Process 1.65 grams 0.00363 N/A perlb 0EndOfLife Landfill(circuitboards) 1.65 grams 0.00363 N/A 3.6 perlb 0.013068Transport Truck,16t 1.65 grams 0.00363 389 0.31 perton-mile 0.000218871Transport Truck,16t 1.65 grams 0.00363 2680 0.31 perton-mile 0.001507902
0.59559477328 LEDWireLeads Material LedWireLeadsPVCJacketedCu 0.41 grams 0.000902 N/A 140 perlb 0.12628
Process 0.41 grams 0.000902 N/A perlb 0EndOfLife Landfill(Circuity) 0.41 grams 0.000902 N/A 3.6 perlb 0.0032472Transport Truck,16t 0.41 grams 0.000902 389 0.31 perton-mile 5.43861E-05Transport Truck,16t 0.41 grams 0.000902 2680 0.31 perton-mile 0.000374691
0.12995627729 LEDPCB(SMD) Material PCBSMD 3.27 grams 0.007194 N/A 320 perlb 2.30208
Process 3.27 grams 0.007194 N/A perlb 0EndOfLife Landfill 3.27 grams 0.007194 N/A 3.6 perlb 0.0258984Transport Truck,16t 3.27 grams 0.007194 389 0.31 perton-mile 0.000433762Transport Truck,16t 3.27 grams 0.007194 2680 0.31 perton-mile 0.002988388
2.3314005530 18650LithiumBattery Material LithiumBattery 42.12 grams 0.092664 N/A 13 perlb 1.204632
Custom18650battery Process 42.12 grams 0.092664 N/A perlb 0EndOfLife Landfill(LawrequiresHazdisp) 42.12 grams 0.092664 N/A perlb 0Transport Truck,16t 42.12 grams 0.092664 389 0.31 perton-mile 0.005587176Transport Truck,16t 42.12 grams 0.092664 2680 0.31 perton-mile 0.038492626
1.24871180131 BatteryPCB(SMD) Material PVCSMD 0.38 grams 0.000836 N/A 320 perlb 0.26752
Process 0.38 grams 0.000836 N/A perlb 0EndOfLife Landfill 0.38 grams 0.000836 N/A 3.6 perlb 0.0030096Transport Truck,16t 0.38 grams 0.000836 389 0.31 perton-mile 5.04066E-05Transport Truck,16t 0.38 grams 0.000836 2680 0.31 perton-mile 0.000347274
0.27092728132 BatteryHeatShrink Material PVCFilm 0.61 grams 0.001342 N/A 13 perlb 0.017446
Process FilmExtrusion 0.61 grams 0.001342 N/A 0.31 perlb 0.00041602EndOfLife Landfill 0.61 grams 0.001342 N/A 0.39 perlb 0.00052338Transport Truck,16t 0.61 grams 0.001342 389 0.31 perton-mile 8.09159E-05Transport Truck,16t 0.61 grams 0.001342 2680 0.31 perton-mile 0.000557467
0.01902378333 RedPaperBatteryInsulator Material Paper(ThickKraft) 0.1 grams 0.00022 N/A 0.71 perlb 0.0001562
Process 0.1 grams 0.00022 N/A perlb 0EndOfLife Landfill 0.1 grams 0.00022 N/A 0.36 perlb 0.0000792Transport Truck,16t 0.1 grams 0.00022 389 0.31 perton-mile 1.32649E-05Transport Truck,16t 0.1 grams 0.00022 2680 0.31 perton-mile 0.000091388
0.00034005334 BatteryFoamsticker Material BatteryFoamStickerPU 0.03 grams 0.000066 N/A 3.1 perlb 0.0002046
Process Extrusion? 0.03 grams 0.000066 N/A perlb 0EndOfLife Landfill 0.03 grams 0.000066 N/A 0.61 perlb 0.00004026Transport Truck,16t 0.03 grams 0.000066 389 0.31 perton-mile 3.97947E-06Transport Truck,16t 0.03 grams 0.000066 2680 0.31 perton-mile 2.74164E-05
0.00027625636 BatteryPCBPaperInsulator Material Paper 0.08 grams 0.000176 N/A 1 perlb 0.000176
Process 0.08 grams 0.000176 N/A perlb 0EndOfLife Landfill 0.08 grams 0.000176 N/A 0.36 perlb 0.00006336Transport Truck,16t 0.08 grams 0.000176 389 0.31 perton-mile 1.06119E-05Transport Truck,16t 0.08 grams 0.000176 2680 0.31 perton-mile 7.31104E-05
0.00032308237 BatteryInfoSticker Material BatteryInfoStickerPVC 0.04 grams 0.000088 N/A 13 perlb 0.001144
Process Calendaring 0.04 grams 0.000088 N/A 0.21 perlb 0.00001848EndOfLife Landfill 0.04 grams 0.000088 N/A 0.39 perlb 0.00003432Transport Truck,16t 0.04 grams 0.000088 389 0.31 perton-mile 5.30596E-06Transport Truck,16t 0.04 grams 0.000088 2680 0.31 perton-mile 3.65552E-05
0.00123866138 BatteryElectricalTape Material BatteryElectricalTape 0.13 grams 0.000286 N/A 13 perlb 0.003718
Process Calendaring 0.13 grams 0.000286 N/A 0.21 perlb 0.00006006EndOfLife Landfill 0.13 grams 0.000286 N/A 0.39 perlb 0.00011154Transport Truck,16t 0.13 grams 0.000286 389 0.31 perton-mile 1.72444E-05Transport Truck,16t 0.13 grams 0.000286 2680 0.31 perton-mile 0.000118804
0.00402564939 BatteryWhiteSticker Material BatteryWhiteStickerPaper 0.09 grams 0.000198 N/A 1 perlb 0.000198
Process 0.09 grams 0.000198 N/A perlb 0EndOfLife Landfill 0.09 grams 0.000198 N/A 0.36 perlb 0.00007128Transport Truck,16t 0.09 grams 0.000198 389 0.31 perton-mile 1.19384E-05Transport Truck,16t 0.09 grams 0.000198 2680 0.31 perton-mile 8.22492E-05
0.00036346840 BatteryWasher Material BatteryWasherPET 0.04 grams 0.000088 N/A 1.8 perlb 0.0001584
Process Thermoforming 0.04 grams 0.000088 N/A 1.4 perlb 0.0001232EndOfLife Landfill 0.04 grams 0.000088 N/A 0.37 perlb 0.00003256Transport Truck,16t 0.04 grams 0.000088 389 0.31 perton-mile 5.30596E-06Transport Truck,16t 0.04 grams 0.000088 2680 0.31 perton-mile 3.65552E-05
0.00035602141 BatteryLeadswithCoupler Material PVCjacketedcopperwire 0.44 grams 0.000968 N/A 140 perlb 0.13552
Process CopperWireDrawing 0.44 grams 0.000968 N/A 1.6 perlb 0.0015488EndOfLife Landfill 0.44 grams 0.000968 N/A perlb 0Transport Truck,16t 0.44 grams 0.000968 389 0.31 perton-mile 5.83656E-05Transport Truck,16t 0.44 grams 0.000968 2680 0.31 perton-mile 0.000402107
0.13752927342 HeatsinkScrew Material Stainlessx2(.11factored) 0.22 grams 0.000484 N/A 13 perlb 0.006292
Process SteelColdForging 0.22 grams 0.000484 N/A 0.56 perlb 0.00027104EndOfLife Landfill 0.22 grams 0.000484 N/A 0.51 perlb 0.00024684Transport Truck,16t 0.22 grams 0.000484 389 0.31 perton-mile 2.91828E-05Transport Truck,16t 0.22 grams 0.000484 2680 0.31 perton-mile 0.000201054
0.00704011642 AdhesiveEstimation Material AdhesiveEstimation(PMMA) 0.09 grams 0.000198 N/A 13 perlb 0.002574
Process 0.09 grams 0.000198 N/A perlb 0EndOfLife Landfill 0.09 grams 0.000198 N/A 0.61 perlb 0.00012078Transport Truck,16t 0.09 grams 0.000198 389 0.31 perton-mile 1.19384E-05Transport Truck,16t 0.09 grams 0.000198 2680 0.31 perton-mile 8.22492E-05
0.00278896842 ThermalGrease Material SiliconeOil+Ceramic 0.09 grams 0.000198 N/A 13 perlb 0.002574
Process Unknown 0.09 grams 0.000198 N/A perlb 0EndOfLife Landfill 0.09 grams 0.000198 N/A 0.39 perlb 0.00007722Transport Truck,16t 0.09 grams 0.000198 389 0.31 perton-mile 1.19384E-05Transport Truck,16t 0.09 grams 0.000198 2680 0.31 perton-mile 8.22492E-05
0.00274540843 ElecticalUse Material USEnergyLowVoltage 12.432 grams 12.432 N/A 1.1 perlb 13.6752
Process grams 0 N/A perlb 0EndOfLife grams 0 N/A perlb 0Transport grams 0 389 0.31 perton-mile 0Transport grams 0 2680 0.31 perton-mile 0
13.6752
Accesories
1 USBcable27",15g Material USBCable 27 inches 27 N/A 0.036 perin 0.972UsedDatacable Process 15 grams 0.033 N/A perlb 0
EndOfLife Landfill(PVC) 15 grams 0.033 N/A 0.39 perlb 0.01287Transport Truck,16t 15 grams 0.033 389 0.31 perton-mile 0.001989735Transport Truck,16t 15 grams 0.033 2680 0.31 perton-mile 0.0137082
1.000567935
Packaging
18 ExteriorBag Material LDPE 4.8 grams 0.01056 N/A 1.5 perlb 0.01584Process FilmBlowMolding 4.8 grams 0.01056 N/A 0.9 perlb 0.009504
EndOfLife Landfill 4.8 grams 0.01056 N/A 0.3 perlb 0.003168Transport Truck,16t 4.8 grams 0.01056 389 0.31 perton-mile 0.000636715Transport Truck,16t 4.8 grams 0.01056 2680 0.31 perton-mile 0.004386624
0.03353533919 ZipTie Material Nylon 0.4 grams 0.00088 N/A 3.6 perlb 0.003168
Process Injection 4.8 grams 0.01056 N/A 0.72 perlb 0.0076032EndOfLife Landfill 0.4 grams 0.00088 N/A 0.6 perlb 0.000528Transport Truck,16t 0.4 grams 0.00088 389 0.31 perton-mile 5.30596E-05Transport Truck,16t 0.4 grams 0.00088 2680 0.31 perton-mile 0.000365552
0.01171781220 PaperBoxPackage Material CardStockPaper 24.9 grams 0.05478 N/A 0.41 perlb 0.0224598
Process ??? 24.9 grams 0.05478 N/A perlb 0EndOfLife Landfill 24.9 grams 0.05478 N/A 0.36 perlb 0.0197208Transport Truck,16t 24.9 grams 0.05478 389 0.31 perton-mile 0.00330296Transport Truck,16t 24.9 grams 0.05478 2680 0.31 perton-mile 0.022755612
0.06823917221 USBBag Material USBBagLDPE 0.84 grams 0.001848 N/A 1.5 perlb 0.002772
Process FilmBlowMolding 0.84 grams 0.001848 N/A 0.9 perlb 0.0016632EndOfLife Landfill 0.84 grams 0.001848 N/A 0.3 perlb 0.0005544Transport Truck,16t 0.84 grams 0.001848 389 0.31 perton-mile 0.000111425Transport Truck,16t 0.84 grams 0.001848 2680 0.31 perton-mile 0.000767659
0.00586868422 TwistTie Material MostlySteel(low?)Wire,Neg.Plastic 0.23 grams 0.000506 N/A 3.5 perlb 0.001771
Process SteelDrawingAuto 0.23 grams 0.000506 N/A 0.18 perlb 0.00009108EndOfLife Landfill 0.23 grams 0.000506 N/A 0.02 perlb 0.00001012Transport Truck,16t 0.23 grams 0.000506 389 0.31 perton-mile 3.05093E-05Transport Truck,16t 0.23 grams 0.000506 2680 0.31 perton-mile 0.000210192
0.002112902
TotalImpact/Lifetime 21.0792Materials 20.48487Processes 0.238977EndofLife 0.159269Transportation 0.16346
21.0465725Lifetimehours
Wear-outLife 1000Hoursusedperyear 520
Impact/Hour 0.02107919
Total Impact: ~21.047
Impact / Hour: ~0.0211
The LCA gives a quantified look at how each individual component adds to the overall impact. Important is the Total Impact and the Impact per Hour of use.
Component Weight ImpactSum of Impacts
Timothy Harris DSID 130Timothy Harris DSID 130 Timothy Harris DSID 130Timothy Harris DSID 130
Research & Ideation
Initial research was conducted by sketching out various form and component alternatives. Miniature LCA’s were done for each of these. These Mini LCA’s give the designer a quick and dirty estimation of what their change does to the impact of that particular system. Once a suitable reduction was found three initial directions were decided upon.
Timothy Harris DSID 130Timothy Harris DSID 130
Initial Directions
The fi rst three directions attempted to include a novel method of attachment to the bike that employed a single hand gesture to remove. They also all included a replaceable battery, as well a USB plug integrated into the device. These individual changes reduced the impact by roughly 20-30%.
The professor found these initial directions to be insuffi ciently broad-minded. While some of the changes were eff ective, I was instructed to develop the form and user interaction, keeping in mind ergonomics and behavior changes.
Timothy Harris DSID 130Timothy Harris DSID 130
Tentative Final Direction
Including the solar panel (which doubles as the mode selector) eliminated a further 1/3rd of the electrical requirement. The form left a lot to be desired, however, so more time was spent refi ning this directions form and its packaging.
A simpler bayonet system of attachment was considered, strong geometry was reduced and the form was adjusted to encourage ergonomic posturing. As well, all technical functionality was
solidifi ed.
Timothy Harris DSID 130 Timothy Harris DSID 130
Final Direction
Further refi ning the form gave the fl ashlight a more approachable, professional, and less coffi n-like shape. Including the SmartStop technology, the solar panel, and material changes brought the reduction to just a hair over 52%.
The attachment system was further simplifi ed with a silicone strap and small HDPE components to attach the holder to the bike. This also gave the product a sportier look, appropriate for the target market.
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Timothy Harris DSID 130
Component Weight ImpactSum of Impacts
Final LCATimHarris-RedesignSBOMSpeculativeRedesignwithSolarPanel.SmartStopmadelargestimprovementbyincreasingrun-timepotential.
Part# PartName Category Amount Unit Pounds Miles OKFP /unit OIP PartOPITotals
Product
1 SiliconeStrap Material Sillicone 7 grams 0.0154 N/A 1.7 perlb 0.02618Process Injection 7 grams 0.0154 N/A 0.72 perlb 0.011088
EndOfLife Landfill 7 grams 0.0154 N/A 0.51 perlb 0.007854Transport Truck,16t 7 grams 0.0154 389 0.31 perton-mile 0.000928543Transport Truck,16t 7 grams 0.0154 2680 0.31 perton-mile 0.00639716
0.0524477032 StrapSnap Material HDPE2 0.2 grams 0.00044 N/A 1.2 perlb 0.000528
Process Injection 0.2 grams 0.00044 N/A 0.72 perlb 0.0003168EndOfLife Landfill 0.2 grams 0.00044 N/A 0.35 perlb 0.000154Transport Truck,16t 0.2 grams 0.00044 389 0.31 perton-mile 2.65298E-05Transport Truck,16t 0.2 grams 0.00044 2680 0.31 perton-mile 0.000182776
0.0012081063 BayonetHarness Material HDPEsec 5 grams 0.011 N/A 1.2 perlb 0.0132
Process Injection 5 grams 0.011 N/A 0.72 perlb 0.00792EndOfLife Landfill 5 grams 0.011 N/A 0.35 perlb 0.00385Transport Truck,16t 5 grams 0.011 389 0.31 perton-mile 0.000663245Transport Truck,16t 5 grams 0.011 2680 0.31 perton-mile 0.0045694
0.0302026454 MainBodyScrew Material Stainlessx2(.32factored) 0.64 grams 0.001408 N/A 13 perlb 0.018304
Process SteelColdForging 0.64 grams 0.001408 N/A 0.56 perlb 0.00078848EndOfLife Landfill 0.64 grams 0.001408 N/A 0.51 perlb 0.00071808Transport Truck,16t 0.64 grams 0.001408 389 0.31 perton-mile 8.48954E-05Transport Truck,16t 0.64 grams 0.001408 2680 0.31 perton-mile 0.000584883
0.0204803395 HeatsinkScrew Material Stainlessx2(.2factored) 0.4 grams 0.00088 N/A 13 perlb 0.01144
Process SteelColdForging 0.4 grams 0.00088 N/A 0.56 perlb 0.0004928EndOfLife Landfill 0.4 grams 0.00088 N/A 0.51 perlb 0.0004488Transport Truck,16t 0.4 grams 0.00088 389 0.31 perton-mile 5.30596E-05Transport Truck,16t 0.4 grams 0.00088 2680 0.31 perton-mile 0.000365552
0.0128002126 SolarPanelPVCrystal Material CIGS 0.5 grams 0.0011 N/A 141 perlb 0.1551
Extrapolatedfrom Process grams 0 N/A 0.21 perlb 0Copper,Gallium,Indium EndOfLife Recycle 0.5 grams 0.0011 N/A 0.37 perlb 0.000407(.04+89+620)/5(atoms) Transport Truck,16t 0.5 grams 0.0011 389 0.31 perton-mile 6.63245E-05
Transport Truck,16t 0.5 grams 0.0011 2680 0.31 perton-mile 0.000456940.156030265
7 SolarPanelSubstrate Material Steel 4 grams 0.0088 N/A 5.3 perlb 0.04664Steel Process SheetRolling 4 grams 0.0088 N/A 0.72 perlb 0.006336
EndOfLife Recycle grams 0 N/A 0.37 perlb 0Transport Truck,16t 4 grams 0.0088 389 0.31 perton-mile 0.000530596Transport Truck,16t 4 grams 0.0088 2680 0.31 perton-mile 0.00365552
0.0571621168 SolarPanelHolder Material ABSSec 4 grams 0.0088 N/A 2.4 perlb 0.02112
Process Injection 4 grams 0.0088 N/A 0.72 perlb 0.006336EndOfLife Landfill 4 grams 0.0088 N/A 0.35 perlb 0.00308Transport Truck,16t 4 grams 0.0088 389 0.31 perton-mile 0.000530596Transport Truck,16t 4 grams 0.0088 2680 0.31 perton-mile 0.00365552
0.0347221169 MainBody Material AbsSec 10 grams 0.022 N/A 1.3 perlb 0.0286
Process Injection 10 grams 0.022 N/A 1.3 perlb 0.0286EndOfLife Landfill 10 grams 0.022 N/A 1.3 perlb 0.0286Transport Truck,16t 10 grams 0.022 389 1.3 perton-mile 0.0055627Transport Truck,16t 10 grams 0.022 2680 1.3 perton-mile 0.038324
0.129686710 GripPortion Material AbsSec 7 grams 0.0154 N/A 1.3 perlb 0.02002
Process Injection 7 grams 0.0154 N/A 1.3 perlb 0.02002EndOfLife Landfill 7 grams 0.0154 N/A 1.3 perlb 0.02002Transport Truck,16t 7 grams 0.0154 389 1.3 perton-mile 0.00389389Transport Truck,16t 7 grams 0.0154 2680 1.3 perton-mile 0.0268268
0.0907806911 BatterySlideCover Material AbsSec 3 grams 0.0066 N/A 1.3 perlb 0.00858
Process Injection 3 grams 0.0066 N/A 1.3 perlb 0.00858EndOfLife Landfill 3 grams 0.0066 N/A 1.3 perlb 0.00858Transport Truck,16t 3 grams 0.0066 389 1.3 perton-mile 0.00166881Transport Truck,16t 3 grams 0.0066 2680 1.3 perton-mile 0.0114972
0.0389060112 Lens Material PC 2.56 grams 0.005632 N/A 3.7 perlb 0.0208384
Process Injection 2.56 grams 0.005632 N/A 0.72 perlb 0.00405504EndOfLife Landfill 2.56 grams 0.005632 N/A 0.61 perlb 0.00343552Transport Truck,16t 2.56 grams 0.005632 389 0.31 perton-mile 0.000339581Transport Truck,16t 2.56 grams 0.005632 2680 0.31 perton-mile 0.002339533
0.03100807413 MainHeatsink Material AluminumSec 12 grams 0.0264 N/A 0.55 perlb 0.01452
Process SheetRolling 12 grams 0.0264 N/A 0.38 perlb 0.010032EndOfLife Recycle grams 0 N/A 0.39 perlb 0Transport Truck,16t 12 grams 0.0264 389 0.31 perton-mile 0.001591788Transport Truck,16t 12 grams 0.0264 2680 0.31 perton-mile 0.01096656
0.03711034814 LED Material LED 1.65 grams 0.00363 N/A 160 perlb 0.5808
Process 1.65 grams 0.00363 N/A perlb 0EndOfLife Landfill(circuitboards) 1.65 grams 0.00363 N/A 3.6 perlb 0.013068Transport Truck,16t 1.65 grams 0.00363 389 0.31 perton-mile 0.000218871Transport Truck,16t 1.65 grams 0.00363 2680 0.31 perton-mile 0.001507902
0.59559477315 LEDWireLeads Material LedWireLeadsPVCJacketedCu 0.41 grams 0.000902 N/A 140 perlb 0.12628
Process 0.41 grams 0.000902 N/A perlb 0EndOfLife Landfill(Circuity) 0.41 grams 0.000902 N/A 3.6 perlb 0.0032472Transport Truck,16t 0.41 grams 0.000902 389 0.31 perton-mile 5.43861E-05Transport Truck,16t 0.41 grams 0.000902 2680 0.31 perton-mile 0.000374691
0.12995627716 LEDPCB(SMD) Material PCBSMDROHS 3.27 grams 0.007194 N/A 85 perlb 0.61149
Process 3.27 grams 0.007194 N/A perlb 0EndOfLife Landfill 3.27 grams 0.007194 N/A 3.6 perlb 0.0258984Transport Truck,16t 3.27 grams 0.007194 389 0.31 perton-mile 0.000433762Transport Truck,16t 3.27 grams 0.007194 2680 0.31 perton-mile 0.002988388
0.6408105517 18650LithiumBattery Material LithiumBattery 42.12 grams 0.092664 N/A 13 perlb 1.204632
Process 42.12 grams 0.092664 N/A perlb 0EndOfLife Recycle(LawrequiresHazdisp) 42.12 grams 0.092664 N/A perlb 0Transport Truck,16t 42.12 grams 0.092664 389 0.31 perton-mile 0.005587176Transport Truck,16t 42.12 grams 0.092664 2680 0.31 perton-mile 0.038492626
1.24871180118 BatteryPCB(SMD) Material PCBSMDROHS 0.38 grams 0.000836 N/A 85 perlb 0.07106
Process 0.38 grams 0.000836 N/A perlb 0EndOfLife Landfill 0.38 grams 0.000836 N/A 3.6 perlb 0.0030096Transport Truck,16t 0.38 grams 0.000836 389 0.31 perton-mile 5.04066E-05Transport Truck,16t 0.38 grams 0.000836 2680 0.31 perton-mile 0.000347274
0.07446728119 USBPCB(SMD) Material PCBSMDROHS 1.63 grams 0.003586 N/A 85 perlb 0.30481
Process 1.63 grams 0.003586 N/A perlb 0EndOfLife Landfill 1.63 grams 0.003586 N/A 3.6 perlb 0.0129096Transport Truck,16t 1.63 grams 0.003586 389 0.31 perton-mile 0.000216218Transport Truck,16t 1.63 grams 0.003586 2680 0.31 perton-mile 0.001489624
0.31942544220 USBPlug Material Steel+Plastic 1.7 grams 0.00374 N/A 0.036 perlb 0.00013464
Componentofdatacable Process 1.7 grams 0.00374 N/A perlb 0EndOfLife Landfill 1.7 grams 0.00374 N/A 3.6 perlb 0.013464Transport Truck,16t 1.7 grams 0.00374 389 0.31 perton-mile 0.000225503Transport Truck,16t 1.7 grams 0.00374 2680 0.31 perton-mile 0.001553596
0.01537773921 BatterySpringContacts Material SteelLowAlloysec 2 grams 0.0044 N/A 3.3 perlb 0.01452
Process SheetRolling 2 grams 0.0044 N/A 0.72 perlb 0.003168EndOfLife Landfill 2 grams 0.0044 N/A 3.6 perlb 0.01584Transport Truck,16t 2 grams 0.0044 389 0.31 perton-mile 0.000265298Transport Truck,16t 2 grams 0.0044 2680 0.31 perton-mile 0.00182776
0.03562105822 BatteryLeadswithCoupler Material PVCjacketedcopperwire 0.44 grams 0.000968 N/A 140 perlb 0.13552
Process CopperWireDrawing 0.44 grams 0.000968 N/A 1.6 perlb 0.0015488EndOfLife Landfill 0.44 grams 0.000968 N/A perlb 0Transport Truck,16t 0.44 grams 0.000968 389 0.31 perton-mile 5.83656E-05Transport Truck,16t 0.44 grams 0.000968 2680 0.31 perton-mile 0.000402107
0.13752927323 HeatsinkScrew Material Stainlessx2(.11factored) 0.22 grams 0.000484 N/A 13 perlb 0.006292
Process SteelColdForging 0.22 grams 0.000484 N/A 0.56 perlb 0.00027104EndOfLife Landfill 0.22 grams 0.000484 N/A 0.51 perlb 0.00024684Transport Truck,16t 0.22 grams 0.000484 389 0.31 perton-mile 2.91828E-05Transport Truck,16t 0.22 grams 0.000484 2680 0.31 perton-mile 0.000201054
0.00704011624 ThermalGrease Material SiliconeOil+Ceramic 0.09 grams 0.000198 N/A 13 perlb 0.002574
Process Unknown 0.09 grams 0.000198 N/A perlb 0EndOfLife Landfill 0.09 grams 0.000198 N/A 0.39 perlb 0.00007722Transport Truck,16t 0.09 grams 0.000198 389 0.31 perton-mile 1.19384E-05Transport Truck,16t 0.09 grams 0.000198 2680 0.31 perton-mile 8.22492E-05
0.00274540825 ElecticalUse Material USEnergyLowVoltage 8.205 grams 8.205 N/A 1.1 perlb 9.0255
Reducedby1/3 Process grams 0 N/A perlb 0fromPVpanel EndOfLife grams 0 N/A perlb 0
Transport grams 0 389 0.31 perton-mile 0Transport grams 0 2680 0.31 perton-mile 0
9.0255
Packaging
20 PaperBoxPackage Material PaperPulp 20 grams 0.044 N/A 0.7 perlb 0.0308Process 20 grams 0.044 N/A perlb 0
EndOfLife Landfill 20 grams 0.044 N/A 0.36 perlb 0.01584Transport Truck,16t 20 grams 0.044 389 0.31 perton-mile 0.00265298Transport Truck,16t 20 grams 0.044 2680 0.31 perton-mile 0.0182776
0.06757058Solar+SingleBatteryReplacement
TotalImpact/Lifetime 12.9929Materials 12.49948
Processes 0.109553EndofLife 0.180748Transportation 0.182181
12.971965Lifetimehours
Wear-outLife 1300Hoursusedperyear 520
Impact/Hour 0.00999454
The Build
The body of the clamp was turned from a section of PVC pipe and the groove to hold the silicone band cut into it. PVC pipe is nowhere near true, so it took a while to get a consistent piece turned.
The piece was split, heated, and opened to the appropriate diameter tube. PVC was chosen to emulate the flexibility of HDPE and approximate its density.
The bayonet would be cut from acrylic rod and sheet and glued onto the base.
Total Impact: ~12.99Impact / Hour: ~0.009
Original product:Total Impact: ~21.047
Impact / Hour: ~0.0211
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Timothy Harris DSID 130Timothy Harris DSID 130
Page Title
A tool from acrylic was built to create the masters that the silicone bands would be cast into.
Initially I planned to use clay, but it was so cold and the clay was too fi rm to even get a minor depression into it. Fortunately, I had some amalgam I had purchased previous for just such an emergency.
The silicone was cast into the amalgam and allowed to cure overnight. I made four separate molds and only two turned out decent.
The Build
I decided to make the packaging from plaster gauze since it can conform to some very tight curves. A negative was built from foam, lubed up with petroleum jelly, and covered with saran wrap to give it a fl uid releasing surface. Strips of gauze were cut and layered over the form paper mache style, and brushed together.
Despite a near-breakdown during its build, it turned out much better than I expected once the water had been driven off from the plaster. The gauze proved to be very durable and modifi cation to it was possible while limited.
The thinness of the gauze approximated the thickness of paper pulp really well. Later I would cover this with thinned bondo to accentuate the texture of the emulated paper.
Timothy Harris DSID 130Timothy Harris DSID 130
Page Title
A block of modulan was squared up and a groove to accommodate the solar panel on top was routed in.
A 15 degree cut was made from one face, and the opening for the LED decal was routed out.
The lower half of the body that will be the grip area was cut off. Using double-stick tape, I reattached it to the main body and made the cuts on the left and right of the body.
The Build
The halves are checked for fit, and part lines are drawn in pencil to mark positioning.
Patching the body, cleaning up part lines, and giving all the corners a smooth radius comes last.
Primed and ready for in-class critique. Later I will paint it, drop the model from my bike while photographing it, then rush a second paint job.
Timothy Harris DSID 130Timothy Harris DSID 130Timothy Harris DSID 130
s o l e i lSolar Rechargeable Bicycle Headl ight
Engineered To Shine
R e - p o w e r w i t h S u n l i g h t
R e c h a r g e w i t h U S B w h e n i t ’ s d a r k
U p t o 1 6 h r s * r u n t i m e w i t h S m a r t S t o p Te c h n o l o g y
W e a t h e r r e s i s t a n t t o k e e p s h i n i n g w h e n t h i n g s g e t s l i c k
6 D i f f e r e n t l i g h t i n t e n s i t i e s f o r a l l c o n d i t i o n s
™
Timothy Harris DSID 130
Integrating the USB cable into the base takes advantage of the on-board charging system already present, and eliminates the need for an extra cable to be included.
Timothy Harris DSID 130Timothy Harris DSID 130
Packaging
*Enlarged to show texture
The pulp packaging allows it to stand alone or be hung from standard retai l hangers
The product is f irmly held inside the package preventing damage during shipping. As well, the exterior and interior sur faces are available for branding.
Timothy Harris DSID 130
3. Manufacturing Innovation Minimize Number of Components
1. Innovation Serve needs provided by associated products
2. Reduced Material Impacts Use recycled or reclaimed materials
4. Reduced Distribution Impacts Reduce product and packaging weight and volume
5. Reduced Behavior and Use Impacts Reduce Energy During Use Design for carbon-neutral or renewable energy6. System Longevity Design for maintenance and easy repair
7. Transitional Systems Design Upgradeable Products
Key improvements and Innovations:
SmartStop Technology
Flexible Solar Panel Integration
Off -Bicycle Behavior Change
User Serviceable Battery
Commuters spend more than 15% of their time at a stop. By dimming the intensity of the LED while at rest, markedly longer run-times can be achieved.
By integrating high-performance fl exible solar panels, more than 30% of the products power requirements may be met. With less intense use, potentially 100% of the energy may be generated from the robust panel.
If you own a bicycle headlamp, then night time vision is important and it will not be the only fl ashlight you own. A quick disconnect system encourages taking the fl ashlight off the bicycle and into the house for security, use, as well as bringing it out of dark storage to increase charge time.
The original product would be discarded once the integrated cell was unable to hold a charge (2-3yrs from typical use). Allowing the user access to changing the 18650 battery increases the products entire life-cycle to 10+ years; closer to bicycle ownership time lines.
Timothy Harris DSID 130
Integrated Solar Panel generates greater than 30% of the products electrical requirement under heavy use. The flexible panel also functions as the mode selector.
A quick disconnect system improves security and encourages off-bicycle use
