section:technology Archives

Toothbrush pops open for recycling in Seymourpowell’s Un-Made concept

British design studio Seymourpowell has put cheap electronic goods under the spotlight with Un-Made, a project imagining four possible ways to design for quick disassembly and recycling.

As part of the project, Seymourpowell devised four automated disassembly mechanism concepts using an electric toothbrush as an example for their animated graphics.

Each of the mechanisms could be built into a product during manufacturing and then activated in a factory at the end of the item’s life.

Rendering of a toothbrush on a white backdrop from Seymour Powell's Un-Made concept — Un-Made suggests automated disassembly mechanisms for an electric toothbrush

The first Un-Made concept is a pin mechanism. Similar to the action of opening a SIM card slot on a smartphone, it involves poking a pin into a small, sealed pinhole on the rear of the product to release the internal components.

The second concept is a vacuum mechanism. It involves placing the product into a vacuum, causing closed cell foams and air-sealed features within it to expand and bust the external housing open.

Third, there is a piston mechanism that works by pushing a piston through a cap on the bottom of a device and forcing all of the internal components upwards until they emerge through the top.

3D graphic showing a conveyer belt of electric toothbrushes being disassembled in Seymour Powell's Un-Made concept — The first concept includes a pin-triggered release mechanism

The final concept involves using UV glue – a type of adhesive that deactivates under ultraviolet light. In this concept, the product is placed into a specially lit chamber to release the clamshell construction.

The Un-Made project was led by Eddie Hamilton, a senior industrial designer at Seymourpowell, who was driven to make the work after researching what electric toothbrush to buy for himself.

“Inevitably I went for the cheap one, at which point Amazon smugly pointed out they’d sold 10k+ of that model last month alone,” said Hamilton.

3D graphic of a series of electric toothbrushes on a conveyer belt. The one on the left is whole, the one in the middle is having its casing stripped from it under a clear dome, and the one on the right has its interior components exposed — Another mechanism uses a vacuum to burst open the product’s external housing

“As an industrial designer, I spend time obsessing over the product I’m working on, typically thinking of it in isolation,” he added.

“But one thing I occasionally fail to remember or adequately picture is the true scale of that product once manufactured. 10,000 units sold per month seems vast.”

Using Amazon’s bestsellers list, Hamilton ascertained that fabric shavers, steam irons, wireless doorbells, wireless computer mice, digital tyre inflators and USB-C adaptors were all items selling in their thousands each month, at a price of less than £20.

While designing products so they can be repaired is important, the associated expense may not be something that customers can justify for small items sold at this price point, Hamilton said.

“Even if we change societal attitudes, the bottom line is whether you should open that cheap toothbrush to replace a failing battery when you only paid £24.99 for it two years ago,” he said.

“I’m optimistic for some product categories to get the ball rolling, namely expensive and bulky items. But I’m also a realist that we need alternative strategies adjacent to repair. This is where we must design for disassembly.”

In Hamilton’s view, disassembly and recycling is a worthy “next best option” to repair for cheaper objects, as it keeps the materials in a circular material flow.

3D graphic showing a conveyer belt of electric toothbrushes being disassembled by a piston mechanism pushing their internal components out from the bottom to the top of the casing from Seymour Powell's Un-Made concept — The piston mechanism disassembles a product by pushing its components up and out

The Un-Made design team took inspiration from Agency of Design’s Design Out Waste project, which looked at three strategies for keeping a toaster out of landfill. But they particularly wanted to explore just how efficient the disassembly process could be made through automation.

The cheaper and easier the process, they say, the more motivation there is for companies to pursue this approach and recover the components and materials inside their devices.

“A huge part of the reason e-waste ends up in landfill is because of product complexity and the inherent challenges involved in their disassembly,” Seymourpowell lead designer Alex Pearce told Dezeen.

“To date, because e-waste has been considered too time-consuming and costly to disassemble – there has been no (commercial) incentive strong enough to make it a viable option.”

3D graphic showing a conveyer belt of electric toothbrushes going into a purple-lit tunnel and emerging on the other side in pieces — The fourth Un-Made concept uses UV light to dissolve the glue holding the device together

The materials inside even cheap devices are valuable, Pearce points out, particularly when there are supply shortages or when it comes to rare-earth minerals.

“When you consider that more gold exists within a ton of e-waste than within a ton of gold ore dug from the ground, a straightforward economic imperative becomes clear for companies who are able to recover and reuse these materials,” said Pearce.

Seymourpowell imagines disassembly taking place either at the manufacturer’s facilities following a take-back procedure, or potentially at a public recycling centre if disassembly processes have been sufficiently standardised.

The London-based studio is known for its innovative product and transport designs, as well as concepts that challenge current norms. Recent projects from the studio have included the two-in-one reusable Bottlecup and a spaceship cabin for Virgin Galactic.

Reference

Sustainable News

Scientists develop hybrid “beef rice” as future meat alternative

By Zarkon Group,23/02/2024

Scientists from South Korea’s Yonsei University have invented what they believe to be a sustainable, high-protein food in the form of “beef rice”, made by growing cow cells in grains of rice.

Tinged a pale pink from the cell culturing process, the hybrid food contains more protein and fat than standard rice while having a low carbon footprint, leading its creators to see it as a potential future meat alternative.

The beef rice was made by inserting muscle and fat stem cells from cows into grains of rice and leaving them to grow in a Petri dish.

Photo of a bowl of pink-coloured rice viewed from above — The hybrid “beef rice” is made by growing cow muscle and fat cells within rice grains

Because the rice grains are porous and have a rich internal structure, the cells can grow there in a similar way to how they would within an animal. A coating of gelatine – in this case, fish-derived – further helps the cells to attach to the rice.

Although beef rice might sound like a form of genetically modified food, there is no altering of DNA in the plants or animals. Instead, this process constitutes a type of cell-cultured or lab-grown meat but with the beef grown inside rice.

In a paper published in the journal Matter, the Yonsei University researchers explain that their process is similar to that used to make a product already sold in Singapore – a cultured meat grown in soy-based textured vegetable protein (TVP).

Soy and nuts are the first foods that have been used for animal cell culturing, they say, but their usefulness is limited because they are common allergens and do not have as much cell-holding potential as rice.

Complex graphic depicting bovine and fat cells inserted into rice grains and the nutritional content table for 100 grams of cultured meat rice — It contains more fat and protein than standard rice

The nutritional gains for their beef rice are also currently small, but the researchers from Yonsei University’s Department of Chemical and Biomolecular Engineering say that with further optimisation, more cells and therefore more protein could be packed in.

The hybrid rice contains 3890 milligrams of protein and 150 milligrams of fat per 100 grams – just 310 milligrams more protein and 10 milligrams more fat than standard rice.

“Although hybrid rice grains still have a lower protein content than beef, advances in technology that can improve the cell capacity of rice grains will undoubtedly improve the nutritional content of hybrid rice,” the researchers said in their paper.

The scientists also believe the product could be inexpensively commercialised and tout the short time frame required to boost nutrition through culturing.

Whereas beef production usually takes one to three years and rice 95 to 250 days, they say their cell culturing process took less than 10 days.

“Imagine obtaining all the nutrients we need from cell-cultured protein rice,” said researcher Sohyeon Park. “I see a world of possibilities for this grain-based hybrid food. It could one day serve as food relief for famine, military ration or even space food.”

If commercialised, the hybrid grain is expected to have a low carbon footprint, similar to growing standard rice, because there would be no need to farm lots of animals. While the stem cells used for the process are extracted from live animals, they can proliferate indefinitely and don’t require animal slaughter.

An obstacle for some may be the taste; the cell culturing process slightly changes the texture and smell of the rice, making it more firm and brittle and introducing odour compounds related to beef, almonds, cream, butter and coconut oil.

Image of hybrid "beef rice" being grown in a petri dish — The meat alternative was grown in a Petri dish

Image of hybrid — The meat alternative was grown in a Petri dish

However, lead researcher Jinkee Hong told the Guardian that the foodstuff tastes “pleasant and novel”.

The team is now planning to continue their research and work to boost the nutritional value of the hybrid rice by stimulating more cell growth.

Lab-grown and cultivated meats have been a subject of great interest and investment since 2013 when the world’s first lab-grown burger was eaten live at a press conference.

However, scaling up production, clearing regulatory hurdles and creating an appealing taste and texture have proven a challenge, and there are few examples on sale anywhere in the world.

In the meantime, speculative designers have explored the issue. Leyu Li recently created three conceptual products that, similar to beef rice, combine lab-grown meat with vegetables, calling them Broccopork, Mushchicken and Peaf.

All images courtesy of Yonsei University.

Reference

Sustainable News

The allure of the ‘bio’ prefix must be taken with some healthy scrutiny

By Zarkon Group,15/02/2024

Biomaterials have the potential to significantly cut carbon emissions but designers should approach them with caution to avoid creating a whole new set of problems, warns Sioban Imms.

The vision of a civilisation based on biomaterials is compelling: products, clothes and buildings made from materials that have been “grown”, rather than derived from polluting, extractive fossil industries. The promise is not only lower emissions, but products that are more in tune with the environment – manufactured objects that are part of the natural cycle of life. And consumers are willing to pay a premium for such ostensibly “sustainable” products – 12 per cent more, according to a recent study by Bain.

However, in a bid to gain competitive advantage, marketing narratives surrounding biomaterials are regularly inflated or gloss over important details. Prefixing “bio” to a material name conjures a sense of being natural, compostable, and better all round for personal and environmental health.

Marketing narratives surrounding biomaterials are regularly inflated

But these claims can unravel, or at least become complicated, when researching a little deeper than the material classification, product name and strapline. A report from RepRisk found a 70 per cent increase in incidents of greenwashing between 2022 and 2023. Incoming legislation in the EU is specifically targeting this issue.

The definition and terminology around biomaterials is still evolving. For clarity, we’re not talking here about biomaterial designed for implanting into the body, but biologically derived materials used in product, fashion and architecture.

Often grown using living micro-organisms like yeast, bacteria, cellulose and mycelium, they can be finely tuned at the nanoscale by engineering DNA sequences to produce specific properties. For example, UK company Colorfix tweaks the DNA of bacteria so that they excrete coloured pigments for dyeing textiles. Microbial manufacturing organisms like these tend to be fed, fermented and modified in controlled environments.

The substitution of fossil-derived, high-carbon materials for biomaterials is urgently important. A recently published study by Radboud Universiteit in the Netherlands concluded that biomaterials reduce greenhouse-gas emissions by an average of 45 per cent compared to fossil-based materials.

But biomaterials are not a magic bullet to the multi-faceted nature crisis industrial civilisation is causing. Especially important is avoiding what are sometimes called “regrettable substitutions” – whereby one material is replaced with another that merely introduces a new set of problems.

For example, BioCane disposable food packaging is an alternative to plastic food packaging made from bagasse – pulped sugarcane-fibre, a waste product from the sugar industry. The design is geared to express its natural origins and circularity, from the subtly flecked, neutral colour and matte finish to the embossed logomark featuring a plant within a gradated circle.

Biomaterials are not a magic bullet to the multi-faceted nature crisis

However, for BioCane to be grease repellant (so it doesn’t fall apart before you’ve consumed the contents) it needs an oleophobic coating, unlike plastic packaging. BioCane uses a polyfluoroalkyl substance (PFAS) for this coating. PFAS are termed “forever chemicals” due to their damaging long-term persistence and accumulation in the environment – not to mention our own bodies.

BioPak, which produces BioCane, transparently publishes information about this on its website, highlighting it as an industry-wide problem. The company also includes a timely pledge to phase out PFAS-containing packaging by June 2024, which happens to coincide with a move to phase out PFAS by the Environmental Protection Agency in the US.

Not all manufacturers are as responsible; it’s common to find unlisted additives – or perhaps a fossil-based lamination to improve a material’s durability – under a headline claim of biological origins.

Bioplastic is another material experiencing significant growth, partly driven by high oil prices making fossil-fuel-derived plastic less competitive. Most bioplastic is made from ethanol, commonly sourced from corn, wheat or sugarcane. Sugarcane, for example, is planted in monocultures in tropical and sub-tropical countries like Brazil. The sugar is extracted, fermented and distilled to produce precursor chemicals for bioplastics.

But to assess the environmental value of using this bioplastic, we need to know about how the crops are managed – for example, the pesticides and synthetic fertilisers used to increase crop yield, the land-clearance practices, and the effect on food prices if the bioplastic became widely adopted. At the end of the product’s life, specialised infrastructure for disposal will need to be in place, further complicating the picture.

Biodegradable bioplastic would seem to offer a solution to the worst ravages of plastic – the alarming buildup of microplastic pollution across the world. How much better if the material could be absorbed back into the environment?

Biodegradable doesn’t mean a material will break down in the environment over useful timescales

The market opportunity for biodegradable plastics is alluring, and forecasts predict that they will account for the majority of the bioplastics market – 62 per cent, by 2028. This opportunity is attracting investment and also the potential for greenwashing as companies vie for a competitive advantage over others.

But biodegradable doesn’t mean a material will break down in the environment over useful timescales. A 2022 UCL study of supposedly “home compostable” bioplastics revealed that 60 per cent did not fully degrade within the tested timespans – a finding that unravels the whole purpose for investing in compostable packaging.

Claims relating to bioplastics were at the crux of a recent legal case brought against US biotech firm Danimer Scientific Inc. The manufacturer of biodegradable products had claimed that its proprietary plastic material Nodax PHA is able to biodegrade not only in industrial composting facilities but in landfill and in the ocean.

Danimer’s share prices rocketed, sparking an investigative report in the Wall Street Journal, which stated that “many claims about Nodax are exaggerated and misleading, according to several experts on biodegradable plastics”. Danimer refutes this statement, but what came out in court was that the company performed biodegradability tests on Nodax in a powdered form, which doesn’t relate to real-world product formats like bottles that have variable thickness.

The legal case was eventually dismissed, but nonetheless the alleged greenwashing spiked Danimer’s share price, shaking investors’ trust in the company and having knock-on effects for the wider industry.

Going forward, manufacturers will need to be transparent about what goes into their products. In the EU, legislation tackling greenwashing in product labelling will come into effect in 2026. The new law is a direct response to the rise in misleading claims that companies use.

When specifying a biomaterial, it’s important to dig into its provenance

It comes after a study commissioned by the bloc found that 53 per cent of green claims on products and services are vague, misleading or unfounded, and 40 per cent have no supporting evidence. In the UK, the Competition and Markets Authority has published the Green Claims Code – a six-point guide to help businesses ensure they are not unwittingly misleading customers.

These two initiatives highlight the importance of using the right language when promoting products and materials, and as the impact of the EU’s legislation ripples through the industry, there will be a natural calibration to more transparency.

The takeaway for designers is that, as ever, the picture is complex. When specifying a biomaterial, it’s important to dig into its provenance, as well as to look at the material use and disposal. The allure of the “bio” prefix from an ethical – and marketing – perspective may be strong, but must be taken along with some healthy scrutiny.

Sioban Imms is a colour, material and finish (CMF) and sustainability strategist with a background in design and manufacturing. She is co-founder of consulting agency Substance and a contributing editor at trend forecasters Stylus and WGSN.

The photo, of MarinaTex designed by Lucy Hughes, is courtesy of the University of Sussex.

Dezeen In Depth
If you enjoy reading Dezeen’s interviews, opinions and features, subscribe to Dezeen In Depth. Sent on the last Friday of each month, this newsletter provides a single place to read about the design and architecture stories behind the headlines.

Reference

Sustainable News

Food-waste dyes bring colour to mycelium leather by Sages and Osmose

By Zarkon Group,31/01/2024

Two British materials companies, Sages and Osmose, have collaborated to dye sheets of mycelium with natural food waste, mimicking the appearance of tanned leather and suggesting a colourful future for the biomaterial.

Osmose is a company making a leather alternative from mycelium – the fibrous underground root network of mushrooms – while Sages makes natural dyes from food waste such as avocado pits, blueberries, red cabbages and onion skins, which are normally applied to textiles.

The two believe they’ve achieved a world first with their collaboration, combining two emerging areas of sustainable material development to colour mycelium without resorting to petroleum-based synthetic dyes, thereby keeping the product non-toxic and able to biodegrade safely in soil.

A small square piece of leather-like material, in a mottled hue of caramel brown — Sages and Osmose have developed a natural dying process for mycelium leather

“There are lots of different types of vegan leather alternatives to traditional leather but the majority of them use either synthetic colourations or they use plasticisers, so they’re non-biodegradable,” said Sages CEO Emily Taylor.

“We wanted to explore an option where we could have a fully biodegradable leather that has also been coloured in a biodegradable and sustainable manner,” she continued.

Companies that prioritise biodegradability have offered mycelium in its natural shades of white and brown or black, which Osmose CEO Aurelie Fontan says is much easier to achieve naturally.

“I think the challenge for mycelium leather was that the offering just wasn’t there in terms of aesthetic,” she said. “When you’re presenting for brands and you’re like ‘we can only do brown’, it’s a little bit boring for them.”

Photo of swatches of mycelium dyed in different shades of tan, pale violet and mulberry — The companies experimented with different food wastes in the dyeing process

“The colour sector is somewhere where you can develop your USP, essentially, which is why working with Sages is so interesting,” Fontan added.

Osmose and Sages have created tan-coloured mycelium sheets using avocado waste, which Sages sources from an importer and guacamole factory in Milton Keynes, where tens of tonnes of leftover pits and skins are produced each week.

It was a new area for both companies, as the food waste dye takes differently to mycelium leather than it does to the usually cellulose-based textiles that Sages has worked with.

The duo collaborated with materials science researchers at the UK’s Cranfield University on the project, for which the researchers focused on how to transfer and fix the dye to the material using “green chemistry” – an area of chemistry that aims to cut out hazardous substances.

In this case, the researchers sought to replace the formic acid and fluorinated acids that are often used in tanning to dissolve the polymers of the leather so it can be infused with dye. Instead, the team developed a method, which they say is significantly less toxic.

After working with Cranfield University, Sages and Osmose expanded the experiment and trialled other waste streams such as blueberries and onion skins to see what colours they could get, producing mycelium swatches in shades of violet and bordeaux.

Taylor and Fontan say they are trying to develop a process for mycelium that is akin to leather tanning, where both colour and durability properties are added in one or two steps. Their equivalent, they say, would be to dye and waterproof the material at the same time.

Close-up of vegan mycelium sheet showing its similarity to the texture of tanned leather — The tan colour was created by using waste avocado pits and skins

Osmose’s focus now is on developing a waterproof coating for their mycelium that, like the dye, is bio-based, non-toxic and able to biodegrade safely in soil. This is notoriously a challenge for plant-based leather alternatives, which almost always rely on a protective synthetic coating.

“It’s really hard to design a solution that fits all materials, which is basically what everyone is struggling with,” said Fontan. “Someone might have pineapple leather and they have their own coating but it doesn’t mean it’s going to work on mushroom and so on.”

Unlike some companies, however, Osmose says it does not want to bring a product with a non-biodegradable coating to market.

“If you’re doing a composite, it will not biodegrade at the end of life, which is compromising all the good work that you’ve been doing before that step,” Fontan said.

Mycelium is one of the most popular emerging leather alternatives. It has already appeared in luxury goods such as a bag by Hermes, clothing by Stella McCartney and trainers by Adidas.

Reference

Architecture

First full-height timber wind turbine opens in Sweden

By Zarkon Group,29/01/2024

The world’s first full-scale timber wind turbine has started turning in Sweden, with a tower built by wood technology company Modvion.

The 105-metre-tall tower, located in the region of Skara, is Modvion‘s first commercial wind turbine tower, and follows on from a smaller 30-metre-high demonstration project the company completed in 2020.

While its rotor blades and generator hub are made of conventional materials, the tower is made of laminated veneer lumber (LVL), a type of engineered wood made of thin veneer strips glued together and often used for beams and load-bearing building structures.

Portrait photograph of a tall wind turbine against a bright blue sky — The tower of a wind turbine in Skara is made of engineered wood

The company says that this type of wood is not only strong enough to withstand the forces of a turning turbine, it is much more environmentally sustainable to build with than the currently used steel.

While wind power plays an important role in providing the world with green renewable energy, there are still ample carbon emissions created during their construction — in part because of the steel towers.

Modvion describes its wood towers as reducing the carbon emissions from wind turbine construction by over 100 per cent, due to the combination of a less emissions-heavy production process and the carbon storage provided by trees.

“Our towers, just in the production of them, they emit 90 per cent less than a steel tower that will do carry the same work,” Modvion chief financial officer Maria-Lina Hedlund told Dezeen. “And then if you add the carbon sequestration, then you actually end up with a minus — so a carbon sink. This is great if we want to reach net zero energy production, and we need to.”

Photo of the inside of a large timber cylinder, with a ladder going up the middle — The type of wood used is laminated veneer lumber

Hedlund, who is also an engineer, describes LVL as having a construction “similar to carbon fibre”, with strips of veneer just three millimetres thick sandwiched and glued together, giving it a high strength-to-weight ratio.

This lightness is a benefit, reducing the amount of material needed overall. With a heavy material, there is a “bad design spiral”, says Hedlund, as the weight of the tower itself adds to the load that it needs to carry.

And while some LVL has all their veneer strips facing in the same direction, Modvion uses its “own recipe” specifying the directions of the fibres, improving the material’s performance even more.

Photo of three people in work gear on top of an incomplete wooden tower — The turbine tower is the tallest so far built by Swedish company Modvion. Photo by Paul Wennerholm

The production process involves timber boards being made to order in a standard LVL plant and then delivered to Modvion’s factory. There, they are glued together into larger modules and bent into a rounded form in a step called lamination, and then very precisely machined to fine-tune the shape.

“In the wood industry, you usually see centimetre tolerances, while we are in the sub-millimetre scale,” said Hedlund.

The modular nature of LVL construction addresses another problem Modvion has observed with steel: that with turbines getting ever bigger to give more power, it’s becoming impossible to transport steel towers to site.

They are built as essentially large cylinders and transported by truck, but the base diameter desired for the tallest towers is getting to be taller than some bridges and roads can allow.

Photo of a giant module of curved laminated veneer lumber being engineered in a factory — The timber is laminated into modules at Modvion’s factory

“We’re now reaching a point where they will not get through anymore,” said Hedlund. “So we will see a transition in the wind power industry to modular construction, because this is the way to get them there. And one of the big advantages of building in the material we do is that it’s naturally built modular.”

While steel could also be built modular, it would require bolts rather than glue to join it together on site, which Hedlund says is a disadvantage.

“Bolts are not very nice when you have so much dynamic loading, because it will loosen over time,” she said. “So first of all, you have to have to put them in place which is a lot of work, and then you have to also service them over the lifetime.”

Photo of a worksite with a man in hi-vis operating machinery in the foreground and a large curved module being lowered into place in front of him — The modules were assembled and glued together on site

The Skara turbine has a capacity of two megawatts, which represents the maximum power output the turbine can achieve under ideal conditions. This is a bit lower than the average capacity for new turbines built in Europe.

On the outside, the tower has a thick white coating that makes it look similar to steel, and it’s rotor blades and generator hub, which are not supplied by Modvion, are made of conventional materials like fibreglass. This may change in the future, however, with another company, Voodin Blades, working on the technology for wooden blades.

Modvion was founded in 2016 by university peers David Olivegren and Otto Lundman. While its current focus is wind turbines, it is dedicated to wooden technology more broadly, and Hedlund told Dezeen that the team believes it has “the world’s strongest joint for timber construction”, which could also be put to other uses.

Another recent milestone for wind power came in the form of a wind-powered cargo ship, which had been retrofitted with two 37.5-metre-tall sails.

Reference

section:technology

Toothbrush pops open for recycling in Seymourpowell’s Un-Made concept

Scientists develop hybrid “beef rice” as future meat alternative

The allure of the ‘bio’ prefix must be taken with some healthy scrutiny

Food-waste dyes bring colour to mycelium leather by Sages and Osmose

First full-height timber wind turbine opens in Sweden

Get in touch

about us

Company info

Useful Links

Newsletter