Green Design Principles: Building Sustainable Solutions

1. Tech/ME 140 Lecture 4 Green Design Principles and SolidWorks Sustainability

2. Green & Sustainability Defined Green technologies mean less energy, use of eco-efficient products, better use of resources which have resulted in lower costs and increased revenues for businesses. Sustainability development meets the needs of the present without compromising the ability of future generations to meet their own need. The goal of sustainable design is to produce products that reduce use of non-renewable resources, minimize environmental impact, and relate people with the natural environment. The concept of green derives from using eco-friendly products that help reduce or eliminate waste and harmful discharges. 

3. Green Design Principles Principle 1: Designers need to strive to ensure that all material and energy inputs and outputs are as inherently nonhazardous as possible. Principle 2: It is better to prevent waste than to treat or clean up waste after it is formed. Principle 3: Separation and purification operations should be designed to minimize energy consumption and materials use. Principle 4: Products, processes, and systems should be designed to maximize mass, energy, space, and time efficiency. Principle 5: Products, processes, and systems should be “output pulled” rather than “input pushed” through the use of energy and materials. Principle 6: Embedded entropy and complexity must be viewed as an investment when making design choices on recycle, reuse, or beneficial disposition. Principle 7: Targeted durability, not immortality, should be a design goal. Principle 8: Design for unnecessary capacity or capability (e.g., “one size fits all”) solutions should be considered a design flaw. Principle 9: Material diversity in multicomponent products should be minimized to promote disassembly and value retention. Principle 10: Design of products, processes, and systems must include integration and interconnectivity with available energy and materials flows. Principle 11: Products, processes, and systems should be designed for performance in a commercial “afterlife”. Principle 12: Material and energy inputs should be renewable rather than depleting.

4. Principle 1 • Designers need to strive to ensure that all material and energy inputs and outputs are as inherently non-hazardous as possible. • Implications: • Human Health • Animal health • Earth and Environment • Pollution • Others

5. Principle 2 • It is better to prevent waste than to treat or clean up waste after it is formed. • Implications: • Human and animal lives • Environment • Reduced cost • Fewer processes • Reduced manpower • DFM • Others

6. Principle 2 (cont.) • “End of pipe” technologies • Containment systems for storage and disposal • Expensive • Constant monitoring • Potential to fail

7. Principle 3 • Separation and purification operations should be a component of the design framework. • Implications: • Simplified processes • Environment • Reduced cost • Fewer processes • Reduced manpower • DFM • Others

8. The catalyst is soluble in one of the reagents and remains soluble when the other reagent is added. As the reaction goes on, and the product builds up, the catalyst precipitates from the mixture as oil. This oil—liquid clathrate—remains to be an active catalyst, as the reagents are able to penetrate into it. When all the reagents are converted into products, the oily catalyst turns into a sticky solid, which can be easily separated and recycled. "A Recyclable Catalyst that Precipitates at the End of the Reaction." Dioumaev, VK, and RM Bullock. July 31, 2003. Nature 424(6948):530-531 Principle 3 (cont.) • Up-front design allows products to self-separate using intrinsic physical/chemical properties such as solubility, volatility, etc.

9. Principle 4 • System components should be designed to maximize mass, energy and temporal efficiency. • Implications: • Efficient design • Environment • Reduced cost • Fewer processes • Reduced manpower • DFM • Others

10. Principle 4 (cont.) • Process intensification • Sophisticated actuator-control systems

11. Principle 5 • System components should be output pulled rather than input pushed through the use of energy and materials.(Le Chatelier’s Principle)

12. Often “drive” a reaction or transformation to completion by adding materials or energy. Principle 5 (cont.) A + B  C + D • Similarly, a reaction can be “pulled” to completion by removing the product without adding materials or energy. A + B  C + D

13. Principle 5 (cont.) • Just in time manufacturing • Production is based on demand • eliminates waste due to overproduction and lowers warehousing costs • supplies are closely monitored and quickly altered to meet changing demands • small and accurate resupply deliveries must be made just as they are needed

14. Principle 6 • Embedded entropy and complexity must be viewed as an investment when making design choices on recycle, reuse or beneficial disposition.

15. Principle 6 (cont.) • The amount of complexity built into a product whether at the macro, micro, or molecular scale is usually a function of resource expenditures. • High complexity, low entropy – reuse • Lower complexity – value-conserving recycling where possible or beneficial disposition • Natural systems can also be recognized as having complexity

16. Principle 6 (cont.) • Case for modular, standardized, platform-based, upgradable design

17. Principle 7 • Targeted durability, not immortality, should be a design goal. • Implications: • Human and animal lives • Environment • Reduced cost • Recyclability • Repair and service • DFM • Others

18. Principle 7 (cont.) • Products that last well beyond their useful commercial life often result in environmental problems ranging from solid waste to persistence and bioaccumulation. • Repair and maintenance must also be considered • Must balance targeted lifetime with durability and robustness in anticipated operating conditions.

19. Principle 7 (cont.) • Biodegradable plastics

20. Principle 8 • Design for unnecessary capacity or capability should be considered a design flaw. This includes engineering “one size fits all” solutions. • Implications: • Efficiency • Reduced cost • Fewer processes • Environment • DFM • Others

21. Principle 8 (cont.) • While product agility and product flexibility can be desirable, the cost in terms of materials and energy for unusable capacity and capability can be high. • There is also a tendency to design for the worst case scenario such that the same product or process can be utilized regardless of spatial or temporal conditions.

22. Principle 8 (cont.) • A single laundry detergent formulation that is intended to work anywhere in the US and must be designed to work in the most extreme hard water conditions • Phosphates were added as builders to remove hardness of water • Phosphates, by their high nutrient value, can cause eutrophication in water bodies

23. Principle 9 • Multi-component products should strive for material unification to promote disassembly and value retention.(minimize material diversity) • Implications: • Recycling • Environment • Reduced cost • Fewer processes • Reduced manpower • DFM/A • Others

24. Principle 9 (cont.) • Selected automobile designers are reducing the number of plastics by developing different forms of polymers to have new material characteristics that improve ease of disassembly and recyclability. • This technology is currently applied to the design of multilayer components, such as door and instrument panels.

25. Principle 9 (cont.) • For example, components can be produced using a single material, such as metallocene polyolefins, that are engineered to have the various and necessary design properties. • Through the use of this monomaterial design strategy, it is no longer necessary to disassemble the door or instrument panel for recovery and recycling

26. Principle 10 • Design of processes and systems must include integration and interconnectivity with available energy and materials flows. • Implications: • Efficiency • Environment • Reduced cost • Fewer processes • Reduced manpower • DFM • Others

27. Principle 10 (cont.)

28. Principle 11 • Performance metrics include designing for performance in commercial “after-life”. • Implications: • Reusability • Human and animal lives • Environment • Reduced cost • Reduced manpower • Others

29. "When we reuse our products — much less recycle them — we keep our costs down significantly," says Rob Fischmann, head of worldwide recycling at Kodak. "The second-time cost for these cameras is essentially zero." Principle 11 (cont.)

30. Principle 12 • Design should be based on renewable and readily available inputs. • Implications: • Earth and the environment • Reduced cost • DFM • Others

31. Principle 12 (cont.) • With cooperative development from Mitsui Chemicals Inc. and Cargill-Dow, LLC, SANYO achieved the world's first bio-plastic (polylactic acid) optical disc in 9/2003. • Use corn as base material to derive polylactic acid with its optical property and exact structure. • Roughly 85 corn kernels is needed to make one disc and one ear of corn to make 10 discs. The world corn production is about 600 million tons, less than 0.1% is needed to make 10 billion discs (current annual worldwide demand).

32. SolidWorks Sustainability Express A Key Feature of SolidWorks Software

33. SolidWorks Sustainability allows a Designer to: • Conduct life cycle assessment (LCA) on parts or assemblies directly within the design window. • Search for comparable materials and see in real time how they affect environmental impact. • Create detailed reports that explain a design’s sustainability.

34. SolidWorks Sustainability Design Features • Intuitive LCA Tool – Conduct comprehensive LCA analyses of parts and assemblies quickly and easily. • Environmental Impact Dashboard – See in real time your product’s air, carbon, energy, and water impacts. • Baseline Measurement – Capture the environmental impact of an existing product as your baseline, and then monitor in real time how your new design compares. • Find Similar Material – Quickly search the material database for alternative materials based on their mechanical properties. • Customizable Reports– Create impressive reports that document the improvements you have made to the environmental impact of your products. • Integrated SolidWorks User Interface – Work productively with a smart, familiar interface that lets you see environmental impacts and make changes directly in the product model.

35. SolidWorks Sustainability Express http://www.treehugger.com/clean-technology/solidworks-sustainability-software-helps-designers-make-the-greenest-products-video.html http://www.treehugger.com/clean-technology/solidworks-sustainability-software-helps-designers-make-the-greenest-products-video.html

36. SolidWorks Sustainability Express http://www.youtube.com/watch?v=3BQHzuJ5Woo

37. Sustainability Task Pane - Parts • When you have a part open, the Sustainablity Task Pane appears with the Material section at the top to let you begin by selecting or modifying the part's material. • This view of the Task Pane is available in either SustainabilityXpress or full Sustainability. • To display the Task Pane, do one of these: • Click SustainabilityXpress (Tools toolbar or Evaluate CommandManager tab) or click Tools > SustainabilityXpress. • Click Sustainability (Tools toolbar or Evaluate CommandManager tab) or click Tools > Sustainability.

38. Key Features of SolidWorks Sustainability Express Material: Class, Name, Recycled Content, Weight, Find Similar, Set Material Manufacturing: Region, Built To Last, Process Use: Region Transportation: Train, Truck, Boat, Plane End of Life: Recycled, Incinerated, Landfill Duration of Use (Length of time the product will be used.) Environmental Impact Areas: Carbon Footprint, Energy Consumption, Air Acidification, Water Eutrophication

39. Auto Makers’ Response to Green Manufacturing and Sustainability

40. Our next class activity will be on SolidWorks Sustainability design. Do your practice before the assignment is given.