Sustainable Electric Toothbrush

Emerging Biomaterials | 1

PROJECTBRIEF

The purpose of this project was to demonstrate an ability to apply research findings from emerging biomaterial studies to the design and development of a feasible

product as a team, from concept to manufacture. The following pages illustrate the process our team executed throughout the ten weeks of product development.


CLASS 3 CLASS 4 WEEKEND CLASS 5 CLASS 6 WEEKEND CLASS 7 CLASS 8 WEEKEND CLASS 9 CLASS 10

PRESENT.#1

PRESENT.#2

PRESENT.FINAL

RESEARCH: BIOMATERIALS

RESEARCH: CONCEPT

CONCEPT DEVELOPMENT

CAD/SKETCH REFINEMENT/PROCESS BOOK

CONCEPTREFINEMENT


LINCOLN NEIGER

MATERIALS:• Bioplastics Based on PLA• Bioplastics Based on PHB• Bioplastics Based on TPS• Bioplastics Based on Cellulose• Bioplastics Based on Vegetable Oils• Lignin-Based Bioplastics• Algae-Based Bioplastics• Bark Cloth Materials• Maise Cob Board (MCB)

RESPONSIBILITIES:• Project Manager• Process Book

RESPONSIBILITIES:• Final Sketches• Bill of Materials

RESPONSIBILITIES:• CAD Model• Renderings

MATERIALS:• Bioplastics from Animal Sources• Acrylic Glass Derived from Sugar• Wood Polymer Composites (WPC)• Coconut-Wood Composites• Bamboo• Heat-Treated Natural Woods

MATERIALS:• Thermo-Hygro-Mechanically

Compacted Wood (THM)• Cork Polymer Composites (CPC)• Almond Polymer Composites (APC)• Algae-Based Materials• Fungus-Based Materials• Natural Fiber Composites (NFC)

MICHAEL NOTO CONSTANTINO PAPATSORIS


MATERIALSRESEARCH


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ACRYLIC GLASS DERIVED FROM SUGAR

Properties: Applications: Suppliers:• light weight• shatterproof• transparency• UV resistant• weatherproof

• acrylic glass• protective goggles• vehicle lights• displays

• currently in development

based on natural raw materials/less energy

consumption and waste during production than

current methods

A new process is in development that employs sugar, alcohol, and fatty acids to create a splinterless material, as clear as glass. This material could potentially replace

acrylic glass. Processing of this material uses less energy and creates less waste than current options.


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ALMOND POLYMERCOMPOSITES (APC)

Properties: Applications: Suppliers:• high strength• durability• homogenous surface texture• airtight• thermoplastic processing

properties• compostable• biodegradable• recycleable

• furniture manufacturing• material coatings• building containers• wall panels• coffins

• Duralmond®• mastAlmond®

replaces wood with plant waste products/raw material

grows quicker than wood/biodegradable

Made of ground almond shells and a biodegradable resin, almond polymer composites (APCs) can be produced faster and easier on account of its renewable raw

material. The almond shells are natural by-product on farms that produce and harvest consumer almonds.


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BAMBOO

Properties: Applications: Suppliers:• high elasticity• very high bending and tensile

strength• 25% harder than oak• susceptible to moisture

damage

• scaffolding• furniture• construction• flooring• household goods• fashion accessories• bicycle frames

• Conbam®• Moso®• Natural Bamboo

highly renewable material/biodegradable/light

construction potential with high durability and stability/

may be used as an alternative to carbon fiber-reinforced

plastics or aluminum

Known for its rapid growth and strength:weight ratio, Bamboo has been used as a building material for centuries.The canes are smoked and heat-treated before use. Its

hollow interior allows for the material to be flexible and light. When used outdoors, bamboo must be protected from moisture, insects, and fungal decay.


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BARK CLOTHMATERIALS

Properties: Applications: Suppliers:• beige to dark brown• individually adjustable

qualities• waterproof• opaque• elastic• tearproof

• light canopies• partitions• lampshades• shoe design• fashion accessories

• Bark Bloth®• Barktex®

based on renewable raw materials/harvested

through small-scale farming in developing regions/

biodegradable

Bark cloth is harvested from the bark of the Mutubu fig tree with the help of Ugandan farmers. It is then sealed with additives to make it wear-resistant. Depending on the

additives used, the bark cloth can employ different characteristics.


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BIOPLASTICS BASED ONALGAE

Properties: Applications: Suppliers:• stable under water• biodegradable• recycleable• mold & bud resistant• low density• flame retardant

• packaging• insulation• items in car interiors

• Algix®• Cereplast®• Verpackungs Zentrum®

based on highly renewable raw materials/emits no

pollutants during processing/can be naturally composted/

recycleable/more expensive to produce/products are said to

maintain an algae smell

Discovered while researching opportunities for bio-fuels based on algaes, algae-based bioplastics offer a highly sustainable alternative to traditional foams

and plastics. Researchers have produced and alginsulate foam which could potentially replace expanded polystyrene.


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BIOPLASTICS BASED ONANIMAL SOURCES

Properties: Applications: Suppliers:• styptic• antibacterial• soluble in water and alkaline

solutions• impermeable to oxygen

• filtration• wound-dressing• surgical thread• toothpaste• food packaging• wood preservative• binding & smoothing agents

for paper production

• Animpol®• Eastern Bioplastics®• N-chitopack®

based on natural raw materials/biodegradable/can be poured to create a film/can

be processed into foams and fibers

Chitin, the main component in the exoskeletons of spiders and crabs, is extracted and produced into chitosan. Chitin is the most notable renewable resource from animals

sources in the production of bioplastics. The inherent properties of these bioplastics make it suitable for use in medical products and biotechnology.


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BIOPLASTICS BASED ONCELLULOSE

Properties: Applications: Suppliers:• good mechanical properties• optical transparancy• self-polishing• good thermal resistance• normally requires a softener

for processing

• writing utensils• umbrella handles• spectacle frames• cigarette filters• giving goggles• steering wheel covers• lampshades• toys• tool handles

• AgriPlast®• Arboform®• Biograde®• Moniflex®• Tencel®• Zelfo®

based on renewable resources/can be recycled/mixing cellulose with other

plastics can produce unique polymer blends/can achieve

various levels of permeability/ideal for injection molding and

extruding

Found in the cell walls of every plant, cellulose is the most common organic compound in the world. Cellulose is ideally suited to producing thermoplastic

bioplastics for translucent components. The most common bioplastics based on cellulose are cellulose acetate (CA) and cellulose triacetate (CTA).


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BIOPLASTICS BASED ONLIGNIN

Properties: Applications: Suppliers:• good mechanical properties• high degree of rigidity• brownish coloring• duroplastic qualities

• construction materials• vehicle dashboards• buttons• toys• disposable cutlery• packaging

• Biome Bioplastic®

derived from renewable raw materials/processing qualities are compared to that of wood/

can be welded together at high temperatures without the

need for adhesives

Comprising 30% of a tree, lignin is the second most common biopolymer found in nature after cellulose. Lignin is extracted from wood shavings and fibers in a

boiling process and then combined with products like methanol and hydrochloric acid to form a resin-like substance, which is then made directly into a duroplastic.


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BIOPLASTICS BASED ONPOLYHYDROXYBUTRIC ACID (PHB)

Properties: Applications: Suppliers:• similar property profile to PP• low oxygen diffusion• UV stability• biocompatibility• high fracture susceptibility • non-transparent• tensile strength

• consumer goods• packaging• adhesives• hard rubbers• automotive industry

• Biocycle®• Biomer®• Enmat®• Metabolix®• Natureplast®• Nodax®

based on renewable sources/biodegradable/can be

processed using traditional plastics processing/rapid

transitions from fluid to solid, resulting in rapid processing/

will likely replace PP in coming years

PLA’s popularity is due to its comparability to PP. The most important representative in polyhydroxyalcanoates polyester, can be found in almost every living

organism. PHB is often mixed with other substances to produce more appropriate blends to negate PHB’s high fracture susceptibility.


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BIOPLASTICS BASED ONPOLYLACTIC ACID (PLA)

Properties: Applications: Suppliers:• similar property profile of PET• low permeability of gases• water-repellent surface• transparent• shiny• relatively low heat stability of

just over 60C

• yogurt containers• food foils• geo-textiles• cosmetic injections• automotive, entertainment,

agriculture, landscaping industries

• Natureworks® Polymer• Ecovio®• Bioflex®• Ecoghr®PLA• Ingeo®

based on renewable resources/recyclable/

compostable under certain circumstances/ideal for

lightweight application/manufacture produces

high CO2 emissions/mechanical resistance and

biodegradability is dependent on the material composition

Polylactic Acid (PLA) is often the center of sustainability discussions as the most popular bio crude plastic due to its potential to replace PET. PLA must be mixed with

aggregates through compounding to suit specific needs. It is produced primarily through the fermentation of sugar syrups and starches.


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BIOPLASTICS BASED ONTHERMOPLASTIC STARCH

Properties: Applications: Suppliers:• liquid absorption• good value for money• excellent gas barrier• energy-efficient production

• medication capsules• packaging foils• yogurt cartons• disposable cutlery• plastic bags• coated cardboard

• Biomax® TPS• BioPar®• BioplastTPS®• Sorona®

based on renewable resources/excellent

biodegradable quality/energy-efficient production/

must be combined with a biodegradable polymer in

order to introduce insoluble qualities

The majority (80%) of global bioplastic production is made up of polymers based on thermoplastic starch. They provide good value for money due to their ubiquity, as

they are sourced from corn, grains, and potatoes. Thermoplastic starch is often just one component of plastics production.


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BIOPLASTICS BASED ONVEGETABLE OILS

Properties: Applications: Suppliers:• bio-based polyamides thermoformable additives can add new properties• bio-based foams flexible light weight hard or soft• bio-based resins similar to synthetic resins biodegradable

• mattresses• foams of various densities

• Akromid® S• Envirez®• Lupranol®• Rubex® NaWaRo• Vestamid Terra®

based on renewable resource/not always biodegradable/

can compete with petroleum-based polyamides/have a

more favorable CO2 footprint than alternatives

Vegetable oils can provide the raw materials required to produce bioplastics, enabling the bio-based production of polyamides

for technical products and resins for fiber compounds or foams.


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COCONUT-WOODCOMPOSITES

Properties: Applications: Suppliers:• minimal shrinkage & swelling• very hard, dense outer layer• no growth rings• dimensional stability• high bending strength

• furniture• parquet flooring• wall panels• lamps• vases• dishes• fashion accessories

• Ekobe®• Kokoshout®

based on natural raw materials/biodegradable/

conventional timber processing technologies are

applicable/oils can be used for intense coloring

Often used in place of exotic woods, coconut wood has no annual rings, rendering the dense, outer five centimeters of the trunk the most useful in composite production.

Coconut wood composites have a 12-18 mm MDF-core, to which the harvested coconut wood is applied.


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CORK POLYMER COMPOSITES (CPC)

Properties: Applications: Suppliers:• unique tactile qualities• adjustable flexibility• thermoplastic processing

qualities• rot-resistant• water-impermeable• noise and vibration

absorption

• medical devices• sport products• orthopedic products• furniture• lamps• vases• bike handles

• Amorim®• Lifecork®• Subertres®• Thermofix®• Vinnex®

based on renewable raw materials/biodegradable/

recyclable/may employ traditional thermoplastic and

wood processing methods

Cork polymer composites (CPCs) are comprised of cork particles suspended within a plastic matrix. The cork particles can range in size from .5-2mm, depending on the

required material flexibility. The combination of these materials creates a material impermeable to water as well and thermoformable.


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LINOLEUM

Properties: Applications: Suppliers:• durable• antibacterial• nonslip• takes pigment well• sensitive to moisture

• flooring• tabletops• surface coverings• high hygienic rooms

• Armstrong®• Forbo®• The Natural Abode®

based on renewable raw materials/compostable/

production produces no waste

Originally introduced to the market in the early 1800s, linoleum has gained recent attention as it is comprised from linseed oil, lime powder, and sawdust. It is mostly

used for surfacing interiors. The material is sensitive to moisture and should not be used in areas that get wet for long periods of time.


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MATERIALS BASED ONALGAE

Properties: Applications: Suppliers:• aesthetic transparency• available worldwide• flame retardant• rapid growth

• wall panels• building containers

• unknown

based on a rapidly renewable raw material/replaces

conventional reinforcing fibers/decomposes when

natural resin matrix is used

Algae based materials are formed through the incorporation of a algae into a resin matrix. Over 200 types of algae are in use in the development of algae-based

materials. Because algae does not require a high level of maintenance in its cultivation, good supple is often readily available.


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MATERIALS BASED ONFUNGUS

Properties: Applications: Suppliers:• heat insulating• sound & shock absorbent• compostable

• packaging• insulation• panelling• table tops

• EcoCradle®• Ecovative®

based on a natural waste material/energy-efficient

manufacturing process/compostable/the growth

process takes place in the dark

Fungus-based materials employ a production method that allows them to grow naturally. The base of the material can be anything from husks of rice to wheat. A fungus

is introduced, growing a network of threads to bring the base material together. The material is dehydrated to stop the growing process.


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MAIZE COBBOARD (MCB)

Properties: Applications: Suppliers:• low density• high durability along axial

direction• similar qualities to particle

board• heat insulation• noise absorption

• furniture surfaces• panelling• insulation• doors

• currently in development

uses agricultural byproducts/50% lighter than

particle board/exceptional noise absorption

Maize cob board employs the use of the natural waste from farms, corn cobs. The cobs are sliced and sandwiched between two boards of various materials. The material

is currently in development and at present is confined to panelling.


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NATURAL FIBERCOMPOSITES (NFC)

Properties: Applications: Suppliers:• light weight• flame retardant• good mechanical strength• rapid growth• available worldwide

• protective helmets• molded parts for cars

• Arbofill®• Biofiber® Wheat• Cellucomp®• Greenline®• NaBasCo®

based on renewable raw materials/can replace

current reinforcement fibers/lighter than current fibers/

compostable

Natural fiber composites are comprised of a combination of fibrous materials found in nature (hemp, flax, coconut) and a synthetic resin. The resin allows

the material to be processed using typical thermoplastic processing procedures. Different combination of materials give these composites various properties.


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HEAT-TREATEDNATURAL WOODS

Properties: Applications: Suppliers:• lower water absorption • high dimensional stability • dark coloring • fungal resistance • good acoustic properties

• facade cladding• solid timber flooring• toys• playground equipment• decking

• Accoya®• Admonter®• OHT Wood®

allows local species to replace exotic, tropical

woods/less energy consumed in procurement/can be

processed through normal manufacturing techniques

Heat-treated natural woods allow for an increased quality of lower-grade lumber in order to make it suitable for outdoor use. Applying heat, pressure, and

acetic anhydride to less-durable woods through the process of acetylation reduces the wood’s water absorption rate, making it more suitable for outdoor use.


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NATURALRUBBER

Properties: Applications: Suppliers:• high degree of elasticity• very resilient• amber color• sticky when wet• becomes brittle with age• susceptible to fungi

• balloons• condoms• tires• rubber springs• engine mountings & seals• hoses & cable coatings

• Linatex®• Yokohama®• Bedell Kraus®

based on renewable materials/biodegradable/

tackiness when wet allows it to be used as an adhesive/only

turpentine or petroleum can dissolve it/rubber trees are currently under attack by a

resilient fungus; scientists are working toward an alternative

source

Natural rubber is extracted from the sap of a rubber tree to form a latex. It consists of natural caoutchouc, water, and sulfur. Its properties make it desirable for

applications requiring elasticity (it can be stretched up to 10 times its size) and resiliency. Natural caoutchouc is used in 40% of all industrial rubber production.


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WOOD POLYMER COMPOSITES (WPC)

Properties: Applications: Suppliers:• even property distribution• low shrinkage• high rigidity & bending

strength• low thermal expansion• high resistance to moisture

• casings for electronics• handles• furniture• outdoor ground surfaces• building components• fashion accessories• bio-urns

• Fasal®• Megawood®• Kupilka®• Fibrolon®• Werzalit®

based on renewable materials/crude, oil-free

matrix materials are biodegradable/maximum

processing temperature should not exceed 200C

Wood Polymer Composites (WPCs) are formed from wood fibers, a plastic matrix, and various additives. Often referred to as ‘liquid wood’, WPCs can be

processed using most traditional thermoplastic processes. Its properties make it particularly desirable for the manufacture of precision components.


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THERMO-HYGRO-MECHANICALLY COMPACTED WOOD (THM)

Properties: Applications: Suppliers:• increased rigidity• weather resistant• 80% less material waste

• building materials• wooden tubes• heavy packaging

• unknown

saves materials compared with round wood/requires less

energy that the manufacture of wood fibers/process can be

reversed and shaped

THM is wood that has been compacted to increase the material’s density. In the heating process, the wood’s biological resistance is increased while the

cell structures remain intact. Processing may be completed with our without mechanical force and his temperature steam.


RESEARCH & OPPORTUNITIES

With sustainability as our primary goal, we set out to research the current context of the electric toothbrush. We found that the electric toothbrush’s highest point of energy consumption occurs during the

processing of its materials and its highest point of environmental impact occurs during the toothbrush’s daily use.

Given the nature of the course and our project timeline, we chose to focus on increasing the electric toothbrush’s sustainability through our choice of materials, the reduction of energy

consumption associated with daily use, and the facilitation of proper product disposal.


Highest Point of Energy Consumption Highest Point of Environmental Impact

Material Production

Energy Usage Over Product Lifecycle

Change the materials used in the production of an electric toothbrush...

Which materials might offer the highest benefit in terms of resources,

recyclability, and energy consumption during production/processing?

How might we provide a solution to the energy loss associated with

vampire energy?

Reduce the amount of energy consumption during the electric toothbrush’s daily use...

Production& Distribution

DailyUse

EOL

Provide avenues forproper disposal...

How might we enable the user

to dispose of their toothbrush

properly?

Opportunity Opportunity Opportunity


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PRODUCT LIFECYCLE

Due to our design opportunities spanning the entire length of the electric toothbrush’s product lifecycle, it quickly became apparent that we must first set

out the lifecycle of our toothbrush before focusing on its form. Following is an explanation of the lifecycle we set forth for our product.


Company Actions Company Actions Material Disposal

User ActionsPurchase

DistributionProduction

Use Charge Separate Parts Package & SendNon-Recyclables

Receive & Dispose Properly Dispose

Parts

Recycle Remaining

Parts

Replace Head


MATERIALSELECTION

Bioplastics Based on Cellulose:We chose to use this material due to its availability, sustainability and recyclability.

Cork Polymer Composites:We chose this material due to its impermeability to water, natural gripping texture, and absorption of vibration.

Natural Rubber:We chose to use this material due to its natural tactile qualities. It is also a more sustainable alternative to industrial rubbers.

Acrylic Glass Derived from Sugar:We chose this material due to its transparant qualities. It is also a more sustainable alternative to traditional acrylics.


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IDEATION

With a clear understanding of our potential materials and a vision set forth for the lifecycle of our product, we moved forward as a team in ideating product form.

Through a series of sketches, we came to a concensus on the direction of the toothbrush’s physical concept and aesthetics.


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CONCEPT REFINEMENT

We continued to refine our sketches and explore the toothbrush’s form, taking the human factors and industry standards into account, until we arrived at a final concept.


FINALCONCEPT


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Part Number: Part Name: Material/Spec: MFG Process: Mat. Supplier: Quanitity:

1 2Handle Shell Injection Molding

Injection Molding

Cellulose Plastic3001D TDS

NatureWorksLLSEllisville, MO, USA

636.238.2111

2 1Handle Grip Cork Polymer CompositeVibrationControl

AmorimMozelos, Portugal+351.227.475.300

3 1Power Button Injection MoldingNatural RubberSVR 20 - TSR

The Standard RubberBinh Doung, Vietnam

+84.974.800.805

4 1Display Screen Injection MoldingAcrylic Glass from SugarUniversity of Duisburg-Essen and

the Helholts Centre for Environmental Research

5 1Brush Bristles SourcedNylonTB-1003

AlibabaShenzhen, Guangdon, China

+86.755.835.6771

6 1Bottom Cap Injection MoldingCellulose Plastic3001D TDS


636.238.2111

7 1Brush Head Injection MoldingCellulose Plastic3001D TDS


636.238.2111

8 1 Gears Injection MoldingNylonTB-1003

EncoFernley, NV, USA

800.873.3626

9 1Motor SourcedAluminumSH Micro DC Motor

Kingly Moto Co. LtdYuandog, Guangdong, China

+86.752.333.5066

10 1Lithium Ion Battery Sourced3.7V: 800mAh; Li-ionHQPR-US

11 1Charging Glass Injection MoldingAcrylic Glass from Sugar University of Duisburg-Essen and

the Helholts Centre for Environmental Research

12 1Charging Base Injection MoldingCellulose Plastic3001D TDS


636.238.2111

13 1Charging Grip Injection MoldingCork Polymer CompositeVibrationControl

AmorimMozelos, Portugal+351.227.475.300

Sustainable Electric Toothbrush

Design

Transcript of Sustainable Electric Toothbrush