Timothy Harris Sustainable Design
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 130
Timothy Harris DSID 130
The Product
The product was disassembled and laid out to visualize the components inside.
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 flash 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 flashlight were unreturned.
Timothy Harris DSID 130
Component List: 1. Large Clasp Collar 2. Clasp Hinge Collar 3. Clasp Nut w/ Insert 4. Clasp Eye Bolt 5. Clasp Nut 6. Main Body Screws 7. Main Button Dust Cover 8. Battery PCB 9. Battery Washer 10. Battery 11.Battery 12. Battery Heat Shrink 13. Upper and Lower Retainer Body 14. Upper and lower Retainer Grip 15. Main Body Forward Half 16. Lens 17. Main Body Heatsink Gasket 18. Heatsink Body 19. LED screws 20. Heatsink Plate 21. Heatsink Screws 22. Battery Retainer 23. Main Body Back Half 24. Battery Heat Shrink (more of it) 25. Slide Retainer Clip 26. Slide Retainer Screw 27. Retainer Washer 28. Slide Hex Nut 29. USB port Dust Cover 30. USB charging cable 31. LED 32. Battery Leads with Coupler 33. LED PCB 34. Zip Tie 35. Twist Tie 36. Battery Electrical Tape 37. Battery Info Sticker 38. Red Paper Battery Insulator 39. Battery PCB insulator 40. Battery Foam Sticker 41. Battery White Sticker 42. “360” Sticker 43. Paper Packaging 44. USB Plastic Bag 45. Exterior Bag
1
2
3 5
4 13
25
34
43
6 14
26
7
15
27
28
16
29
17
8
9
18
19
36
44
20
31
30
35
10
37
11
21
22
23
32
38
39
12
24
33
40
41
42
45
Timothy Harris DSID 130
Transport Truck, 16t
Tim Harris - Rechargable Bicycle Flashlight
Research LCA
Notes-
Parts are mounted on paper
Part #
Part Name
Product says "engineered and Assembled in the USA." Phone call confirmed place of assembly, but not manufacture. Transport is caluclated from facility to the home (389 mi), as well as coast to coast (2680 mi). Category Amount Unit Pounds Miles OKFP /unit
Component Weight
Product 1
2
3
4
5
6
7
8
9
10
11
12
13
14
Large Clasp Collar
Clasp Eye Bolt
Clasp Nut
Clasp Nut w/ Insert
Clasp Hinge Collar
Slide Retainer Clip
Retainer Washer
Slide Hex Lock Nut (nylon)
Rubber Grip Upper
Retainer Grip Lower
Retauber Screw
Retainer Body Upper
Retainer Body Lower
Main Body Dust Cover
Material Process End Of Life Transport Transport
Stainless Stainless Sheet Rolling Landfill Truck, 16t Truck, 16t
Material Process End Of Life Transport Transport
15 OIP
Impact
1.12 1.12 1.12 1.12 1.12
grams grams grams grams grams
0.002464 0.002464 0.002464 0.002464 0.002464
N/A N/A N/A 389 2680
13 per lb 1.2 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.032032 0.0029568 0.00125664 0.000148567 0.003929684
Stainless Steel Cold Forging Landfill Truck, 16t Truck, 16t
4.3 4.3 4.3 4.3 4.3
grams grams grams grams grams
0.00946 0.00946 0.00946 0.00946 0.00946
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.12298 0.0052976 0.0048246 0.000570391 0.003929684
Material Process End Of Life Transport Transport
Stainless and Nylon Injection Landfill Truck, 16t Truck, 16t
2.5 2.5 2.5 2.5 2.5
grams grams grams grams grams
0.0055 0.0055 0.0055 0.0055 0.0055
N/A N/A N/A 389 2680
3.5 per lb 0.72 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01925 0.00396 0.002805 0.000331623 0.0022847
Material Process End Of Life Transport Transport
Aluminum AL Metal Working Landfill Truck, 16t Truck, 16t
0.2 0.2 0.2 0.2 0.2
grams grams grams grams grams
0.00044 0.00044 0.00044 0.00044 0.00044
N/A N/A N/A 389 2680
13 2.8 0.39
per lb per lb per lb per ton-mile 0.31 per ton-mile
0.00572 0.001232 0.0001716 0 0.000182776
Material Process End Of Life Transport Transport
Stainless Stainless Sheet Rolling Landfill Truck, 16t Truck, 16t
0.55 0.55 0.55 0.55
grams grams grams grams grams
0.00121 0.00121 0.00121 0.00121 0
N/A N/A N/A 389 2680
13 per lb 1.2 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01573 0.001452 0.0006171 7.2957E-05 0
Material Process End Of Life Transport Transport
ABS Injection Landfill Truck, 16t Truck, 16t
4.51 4.51 4.51 4.51 4.51
grams grams grams grams grams
0.009922 0.009922 0.009922 0.009922 0.009922
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0238128 0.00714384 0.0034727 0.000598247 0.004121599
Material Process End Of Life Transport Transport
Nylon Calendaring Landfill Truck, 16t Truck, 16t
0.07 0.07 0.07 0.07 0.07
grams grams grams grams grams
0.000154 0.000154 0.000154 0.000154 0.000154
N/A N/A N/A 389 2680
3.5 per lb 0.21 per lb 0.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.000539 0.00003234 0.0000924 9.28543E-06 6.39716E-05
Material Process End Of Life Transport Transport
Stainless and Nylon Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.44 0.44 0.44 0.44 0.44
grams grams grams grams grams
0.000968 0.000968 0.000968 0.000968 0.000968
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.012584 0.00054208 0.00049368 5.83656E-05 0.000402107
Material Process End Of Life Transport Transport
Vinyl Injection Landfill Truck, 16t Truck, 16t
1.7 1.7 1.7 1.7 1.7
grams grams grams grams grams
0.00374 0.00374 0.00374 0.00374 0.00374
N/A N/A N/A 389 2680
13 per lb 0.72 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.04862 0.0026928 0.0014586 0.000225503 0.001553596
Material Process End Of Life Transport Transport
Vinyl Injection Landfill Truck, 16t Truck, 16t
1.15 1.15 1.15 1.15 1.15
grams grams grams grams grams
0.00253 0.00253 0.00253 0.00253 0.00253
N/A N/A N/A 389 2680
13 per lb 0.72 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.03289 0.0018216 0.0009867 0.000152546 0.001050962
Material Process End Of Life Transport Transport
Stainless Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.81 0.81 0.81 0.81 0.81
grams grams grams grams grams
0.001782 0.001782 0.001782 0.001782 0.001782
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.023166 0.00099792 0.00069498 0.000107446 0.000740243
Material Process End Of Life Transport Transport
ABS Injection Landfill Truck, 16t Truck, 16t
7.85 7.85 7.85 7.85 7.85
grams grams grams grams grams
0.01727 0.01727 0.01727 0.01727 0.01727
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.041448 0.0124344 0.0060445 0.001041295 0.007173958
Material Process End Of Life Transport Transport
ABS Injection Landfill Truck, 16t Truck, 16t
6.67 6.67 6.67 6.67 6.67
grams grams grams grams grams
0.014674 0.014674 0.014674 0.014674 0.014674
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0352176 0.01056528 0.0051359 0.000884769 0.00609558
Material Process End Of Life Transport
Silicone Injection Landfill (Elastomer) Truck, 16t
0.61 0.61 0.61 0.61
grams grams grams grams
0.001342 0.001342 0.001342 0.001342
N/A N/A N/A 389
1.7 per lb 0.72 per lb 0.39 per lb 0.31 per ton-mile
0.0022814 0.00096624 0.00052338 8.09159E-05
Main Body Button Cover
Part OPI Totals
Sum of Impacts
0.040323691
0.137602275
0.028631323
0.007306376
0.017872057
0.039149186
0.000736997
0.014080233
0.054550499
0.036901808
0.025706588
0.068142153
0.057899128
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Main Body Screw
Main Body Heatsink Gasket
Heatsink Screw
"360" Mylar Sticker
Main Body Forward Half
Main Body Back Half
Lens
Lens Gasket
Main Heatsink
Heatsink Plate
Battery Retainer
LED
LED Wire Leads
LED PCB (SMD)
0.61
grams
0.001342
2680
0.31 per ton-mile
0.000557467
Material Process End Of Life Transport Transport
Silicone Injection Landfill Truck, 16t Truck, 16t
0.84 0.84 0.84 0.84 0.84
grams grams grams grams grams
0.001848 0.001848 0.001848 0.001848 0.001848
N/A N/A N/A 389 2680
1.7 per lb 0.72 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0031416 0.00133056 0.00072072 0.000111425 0.000767659
Material Process End Of Life Transport Transport
Stainless x3 (.32 factored) Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.96 0.96 0.96 0.96 0.96
grams grams grams grams grams
0.002112 0.002112 0.002112 0.002112 0.002112
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.027456 0.00118272 0.00107712 0.000127343 0.000877325
Material Process End Of Life Transport Transport
Silicone Injection Landfill Truck, 16t Truck, 16t
0.33 0.33 0.33 0.33 0.33
grams grams grams grams grams
0.000726 0.000726 0.000726 0.000726 0.000726
N/A N/A N/A 389 2680
1.7 per lb 0.72 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0012342 0.00052272 0.00028314 4.37742E-05 0.00030158
Material Process End Of Life Transport Transport
Stainless x2 (.2 factored) Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.4 0.4 0.4 0.4 0.4
grams grams grams grams grams
0.00088 0.00088 0.00088 0.00088 0.00088
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01144 0.0004928 0.0004488 5.30596E-05 0.000365552
Material Process End Of Life Transport Transport
PET Calendaring Landfill Truck, 16t Truck, 16t
0.001 0.001 0.001 0.001 0.001
grams grams grams grams grams
0.0000022 0.0000022 0.0000022 0.0000022 0.0000022
N/A N/A N/A 389 2680
1.8 per lb 0.21 per lb 0.37 per lb 0.31 per ton-mile 0.31 per ton-mile
0.00000396 0.000000462 0.000000814 1.32649E-07 9.1388E-07
Material Process End Of Life Transport Transport
ABS Injection Landfill Truck, 16t Truck, 16t
10.23 10.23 10.23 10.23 10.23
grams grams grams grams grams
0.022506 0.022506 0.022506 0.022506 0.022506
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0540144 0.01620432 0.0078771 0.001356999 0.009348992
Material Process End Of Life Transport Transport
ABS Injection Landfill Truck, 16t Truck, 16t
21.11 21.11 21.11 21.11 21.11
grams grams grams grams grams
0.046442 0.046442 0.046442 0.046442 0.046442
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.1114608 0.03343824 0.0162547 0.00280022 0.019292007
Material Process End Of Life Transport Transport
PC Injection Landfill Truck, 16t Truck, 16t
2.56 2.56 2.56 2.56 2.56
grams grams grams grams grams
0.005632 0.005632 0.005632 0.005632 0.005632
N/A N/A N/A 389 2680
3.7 per lb 0.72 per lb 0.61 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0208384 0.00405504 0.00343552 0.000339581 0.002339533
Material Process End Of Life Transport Transport
Silicone Injection Landfill Truck, 16t Truck, 16t
0.92 0.92 0.92 0.92 0.92
grams grams grams grams grams
0.002024 0.002024 0.002024 0.002024 0.002024
N/A N/A N/A 389 2680
1.7 per lb 0.72 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0034408 0.00145728 0.00078936 0.000122037 0.00084077
Material Process End Of Life Transport Transport
Aluminum Die Cast (Aluminuim Metal Working) Landfill Truck, 16t Truck, 16t
13.46 13.46 13.46 13.46 13.46
grams grams grams grams grams
0.029612 0.029612 0.029612 0.029612 0.029612
N/A N/A N/A 389 2680
13 per lb 2.8 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.384956 0.0829136 0.01154868 0.001785456 0.012300825
Material Process End Of Life Transport Transport
Aluminum Aluminum Metal Working (stamped) Landfill Truck, 16t Truck, 16t
3.22 3.22 3.22 3.22 3.22
grams grams grams grams grams
0.007084 0.007084 0.007084 0.007084 0.007084
N/A N/A N/A 389 2680
13 per lb 2.8 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.092092 0.0198352 0.00276276 0.00042713 0.002942694
Material Process End Of Life Transport Transport
ABS Injection Landfill Truck, 16t Truck, 16t
2.62 2.62 2.62 2.62 2.62
grams grams grams grams grams
0.005764 0.005764 0.005764 0.005764 0.005764
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0138336 0.00415008 0.0020174 0.00034754 0.002394366
Material Process End Of Life Transport Transport
LED
1.65 1.65 1.65 1.65 1.65
grams grams grams grams grams
0.00363 0.00363 0.00363 0.00363 0.00363
N/A N/A N/A 389 2680
160
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.5808 0 0.013068 0.000218871 0.001507902
0.41 0.41 0.41 0.41 0.41
grams grams grams grams grams
0.000902 0.000902 0.000902 0.000902 0.000902
N/A N/A N/A 389 2680
140
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.12628 0 0.0032472 5.43861E-05 0.000374691
3.27 3.27 3.27 3.27 3.27
grams grams grams grams grams
0.007194 0.007194 0.007194 0.007194 0.007194
N/A N/A N/A 389 2680
320
2.30208 0 0.0258984 0.000433762 0.002988388
Material Process End Of Life Transport Transport Material Process End Of Life Transport Transport
Landfill (circuit boards) Truck, 16t Truck, 16t Led Wire Leads PVC Jacketed Cu Landfill (Circuity) Truck, 16t Truck, 16t PCB SMD Landfill Truck, 16t Truck, 16t
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.004409403
0.006071964
0.030720508
0.002385415
0.012800212
6.28253E-06
0.088801812
30
31
32
33
34
36
37
18650 Lithium Battery Custom 18650 battery
Battery PCB (SMD)
Battery Heat Shrink
Red Paper Battery Insulator
Battery Foam sticker
Battery PCB Paper Insulator
Battery Info Sticker
Material Process End Of Life Transport Transport
Lithium Battery
Material Process End Of Life Transport Transport
PVC SMD
42.12 42.12 42.12 42.12 42.12
grams grams grams grams grams
0.092664 0.092664 0.092664 0.092664 0.092664
N/A N/A N/A 389 2680
per lb per lb per lb 0.31 per ton-mile 0.31 per ton-mile
1.204632 0 0 0.005587176 0.038492626
grams grams grams grams grams
0.000836 0.000836 0.000836 0.000836 0.000836
N/A N/A N/A 389 2680
320
Landfill Truck, 16t Truck, 16t
0.38 0.38 0.38 0.38 0.38
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.26752 0 0.0030096 5.04066E-05 0.000347274
Material Process End Of Life Transport Transport
PVC Film Film Extrusion Landfill Truck, 16t Truck, 16t
0.61 0.61 0.61 0.61 0.61
grams grams grams grams grams
0.001342 0.001342 0.001342 0.001342 0.001342
N/A N/A N/A 389 2680
13 per lb 0.31 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.017446 0.00041602 0.00052338 8.09159E-05 0.000557467
Material Process End Of Life Transport Transport
Paper (Thick Kraft)
grams grams grams grams grams
0.00022 0.00022 0.00022 0.00022 0.00022
N/A N/A N/A 389 2680
0.71
Landfill Truck, 16t Truck, 16t
0.1 0.1 0.1 0.1 0.1
0.0001562 0 0.0000792 1.32649E-05 0.000091388
Material Process End Of Life Transport Transport
Battery Foam Sticker PU Extrusion? Landfill Truck, 16t Truck, 16t
0.03 0.03 0.03 0.03 0.03
grams grams grams grams grams
0.000066 0.000066 0.000066 0.000066 0.000066
N/A N/A N/A 389 2680
3.1
Material Process End Of Life Transport Transport
Paper Landfill Truck, 16t Truck, 16t
0.08 0.08 0.08 0.08 0.08
grams grams grams grams grams
0.000176 0.000176 0.000176 0.000176 0.000176
N/A N/A N/A 389 2680
per lb per lb 0.36 per lb 0.31 per ton-mile 0.31 per ton-mile
0.000176 0 0.00006336 1.06119E-05 7.31104E-05
Material Process End Of Life Transport Transport
Battery Info Sticker PVC Calendaring Landfill Truck, 16t Truck, 16t
0.04 0.04 0.04 0.04 0.04
grams grams grams grams grams
0.000088 0.000088 0.000088 0.000088 0.000088
N/A N/A N/A 389 2680
13 per lb 0.21 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.001144 0.00001848 0.00003432 5.30596E-06 3.65552E-05
13 per lb 0.21 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.003718 0.00006006 0.00011154 1.72444E-05 0.000118804
Landfill (Law requires Haz disp) Truck, 16t Truck, 16t
13
per lb per lb 0.36 per lb 0.31 per ton-mile 0.31 per ton-mile per lb per lb 0.61 per lb 0.31 per ton-mile 0.31 per ton-mile 1
0.0002046 0 0.00004026 3.97947E-06 2.74164E-05
0.183245967
38
Battery Electrical Tape
Material Process End Of Life Transport Transport
Battery Electrical Tape Calendaring Landfill Truck, 16t Truck, 16t
0.13 0.13 0.13 0.13 0.13
grams grams grams grams grams
0.000286 0.000286 0.000286 0.000286 0.000286
N/A N/A N/A 389 2680
0.031008074
39
Battery White Sticker
Material Process End Of Life Transport Transport
Battery White Sticker Paper Landfill Truck, 16t Truck, 16t
0.09 0.09 0.09 0.09 0.09
grams grams grams grams grams
0.000198 0.000198 0.000198 0.000198 0.000198
N/A N/A N/A 389 2680
per lb per lb per lb 0.36 0.31 per ton-mile 0.31 per ton-mile
0.000198 0 0.00007128 1.19384E-05 8.22492E-05
Material Process End Of Life Transport Transport
Battery Washer PET Thermoforming Landfill Truck, 16t Truck, 16t
0.04 0.04 0.04 0.04 0.04
grams grams grams grams grams
0.000088 0.000088 0.000088 0.000088 0.000088
N/A N/A N/A 389 2680
1.8 per lb 1.4 per lb 0.37 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0001584 0.0001232 0.00003256 5.30596E-06 3.65552E-05
Material Process End Of Life Transport Transport
PVC jacketed copper wire Copper Wire Drawing Landfill Truck, 16t Truck, 16t
0.44 0.44 0.44 0.44 0.44
grams grams grams grams grams
0.000968 0.000968 0.000968 0.000968 0.000968
N/A N/A N/A 389 2680
140 1.6
per lb per lb per lb 0.31 per ton-mile 0.31 per ton-mile
0.13552 0.0015488 0 5.83656E-05 0.000402107
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.006292 0.00027104 0.00024684 2.91828E-05 0.000201054
0.006650247
0.49350456
40
41
Battery Washer
Battery Leads with Coupler
0.118059783
42
Heatsink Screw
Material Process End Of Life Transport Transport
Stainless x2 (.11 factored) Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.22 0.22 0.22 0.22 0.22
grams grams grams grams grams
0.000484 0.000484 0.000484 0.000484 0.000484
N/A N/A N/A 389 2680
0.022742986
42
Adhesive Estimation
Material Process End Of Life Transport Transport
Adhesive Estimation (PMMA) Landfill Truck, 16t Truck, 16t
0.09 0.09 0.09 0.09 0.09
grams grams grams grams grams
0.000198 0.000198 0.000198 0.000198 0.000198
N/A N/A N/A 389 2680
Silicone Oil + Ceramic Unknown Landfill Truck, 16t Truck, 16t
0.09 0.09 0.09 0.09 0.09
grams grams grams grams grams
0.000198 0.000198 0.000198 0.000198 0.000198
N/A N/A N/A 389 2680
12.432
grams grams grams grams grams
12.432 0 0 0 0
N/A N/A N/A 389 2680
0.595594773
42
Thermal Grease
Material Process End Of Life Transport Transport
0.129956277
43
Electical Use
Material US Energy Low Voltage Process End Of Life Transport Transport
1
13
per lb per lb 0.61 per lb 0.31 per ton-mile 0.31 per ton-mile per lb per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.002574 0 0.00012078 1.19384E-05 8.22492E-05
13
0.002574 0 0.00007722 1.19384E-05 8.22492E-05
1.1
13.6752 0 0 0 0
per lb per lb per lb 0.31 per ton-mile 0.31 per ton-mile
2.33140055
Accesories 1
USB cable 27", 15g Used Data cable
1.248711801
Material Process End Of Life Transport Transport
USB Cable Landfill (PVC) Truck, 16t Truck, 16t
27 15 15 15 15
inches grams grams grams grams
27 0.033 0.033 0.033 0.033
N/A N/A N/A 389 2680
0.036
Packaging 0.270927281
0.019023783
0.000340053
0.000276256
0.000323082
0.001238661
0.004025649
0.000363468
per in per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.972 0 0.01287 0.001989735 0.0137082
18
Exterior Bag
Material Process End Of Life Transport Transport
LDPE Film Blow Molding Landfill Truck, 16t Truck, 16t
4.8 4.8 4.8 4.8 4.8
grams grams grams grams grams
0.01056 0.01056 0.01056 0.01056 0.01056
N/A N/A N/A 389 2680
1.5 per lb 0.9 per lb 0.3 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01584 0.009504 0.003168 0.000636715 0.004386624
19
Zip Tie
Material Process End Of Life Transport Transport
Nylon Injection Landfill Truck, 16t Truck, 16t
0.4 4.8 0.4 0.4 0.4
grams grams grams grams grams
0.00088 0.01056 0.00088 0.00088 0.00088
N/A N/A N/A 389 2680
3.6 per lb 0.72 per lb 0.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.003168 0.0076032 0.000528 5.30596E-05 0.000365552
20
Paper Box Package
Material Process End Of Life Transport Transport
Card Stock Paper ??? Landfill Truck, 16t Truck, 16t
24.9 24.9 24.9 24.9 24.9
grams grams grams grams grams
0.05478 0.05478 0.05478 0.05478 0.05478
N/A N/A N/A 389 2680
0.41
per lb per lb 0.36 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0224598 0 0.0197208 0.00330296 0.022755612
21
USB Bag
Material Process End Of Life Transport Transport
USB Bag LDPE Film Blow Molding Landfill Truck, 16t Truck, 16t
0.84 0.84 0.84 0.84 0.84
grams grams grams grams grams
0.001848 0.001848 0.001848 0.001848 0.001848
N/A N/A N/A 389 2680
1.5 per lb 0.9 per lb 0.3 per lb 0.31 per ton-mile 0.31 per ton-mile
0.002772 0.0016632 0.0005544 0.000111425 0.000767659
22
Twist Tie
Material Process End Of Life Transport Transport
Mostly Steel (low?) Wire, Neg. Plastic Steel Drawing Auto Landfill Truck, 16t Truck, 16t
0.23 0.23 0.23 0.23 0.23
grams grams grams grams grams
0.000506 0.000506 0.000506 0.000506 0.000506
N/A N/A N/A 389 2680
3.5 per lb 0.18 per lb 0.02 per lb 0.31 per ton-mile 0.31 per ton-mile
0.001771 0.00009108 0.00001012 3.05093E-05 0.000210192
Total Impact / Lifetime Materials 20.48487 Processes 0.238977 End of Life 0.159269 Transportation 0.16346 Lifetime hours Wear-out Life Hours used per year Impact /Hour
1.000567935
0.033535339
0.011717812
0.068239172
0.005868684
0.002112902
21.0792
21.0465725 1000 520 0.02107919
0.000356021
0.137529273
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.
0.007040116
Total Impact: ~21.047 0.002788968
Impact / Hour: ~0.0211
0.002745408
13.6752
Timothy 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 130
Timothy Harris DSID 130
Initial Directions
The first 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 insuďŹƒciently broad-minded. While some of the changes were effective, I was instructed to develop the form and user interaction, keeping in mind ergonomics and behavior changes.
Timothy Harris DSID 130
Timothy 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 refining 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 solidified. Timothy Harris DSID 130
Timothy Harris DSID 130
Final Direction
Further refining the form gave the flashlight a more approachable, professional, and less coďŹƒn-like shape. Including the SmartStop technology, the solar panel, and material changes brought the reduction to just a hair over 52%.
E W D I D ! T I Timothy Harris DSID 130
The attachment system was further simplified 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.
Timothy Harris DSID 130
Tim Harris - Redesign SBOM Speculative
Final LCA
Redesign with Solar Panel. SmartStop made largest improvement by increasing run-time potential. Part #
Part Name
Category
Product 1
2
3
4
5
6
7
Silicone Strap
Strap Snap
Bayonet Harness
Main Body Screw
Heatsink Screw
Solar Panel PV Crystal Extrapolated from Copper, Gallium, Indium (.04+89+620)/5 (atoms)
Solar Panel Substrate Steel
Material Process End Of Life Transport Transport
Sillicone Injection Landfill Truck, 16t Truck, 16t
Material Process End Of Life Transport Transport
Amount
Unit
Pounds
Component Weight
Miles
7 7 7 7 7
grams grams grams grams grams
0.0154 0.0154 0.0154 0.0154 0.0154
N/A N/A N/A 389 2680
HDPE 2 Injection Landfill Truck, 16t Truck, 16t
0.2 0.2 0.2 0.2 0.2
grams grams grams grams grams
0.00044 0.00044 0.00044 0.00044 0.00044
Material Process End Of Life Transport Transport
HDPE sec Injection Landfill Truck, 16t Truck, 16t
5 5 5 5 5
grams grams grams grams grams
Material Process End Of Life Transport Transport
Stainless x2 (.32 factored) Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.64 0.64 0.64 0.64 0.64
Material Process End Of Life Transport Transport
Stainless x2 (.2 factored) Steel Cold Forging Landfill Truck, 16t Truck, 16t
Material Process End Of Life Transport Transport Material Process End Of Life Transport Transport
Steel Sheet Rolling Recycle Truck, 16t Truck, 16t
OKFP
/unit
Impact
OIP
1.7 per lb 0.72 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.02618 0.011088 0.007854 0.000928543 0.00639716
N/A N/A N/A 389 2680
1.2 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.000528 0.0003168 0.000154 2.65298E-05 0.000182776
0.011 0.011 0.011 0.011 0.011
N/A N/A N/A 389 2680
1.2 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0132 0.00792 0.00385 0.000663245 0.0045694
grams grams grams grams grams
0.001408 0.001408 0.001408 0.001408 0.001408
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.018304 0.00078848 0.00071808 8.48954E-05 0.000584883
0.4 0.4 0.4 0.4 0.4
grams grams grams grams grams
0.00088 0.00088 0.00088 0.00088 0.00088
N/A N/A N/A 389 2680
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01144 0.0004928 0.0004488 5.30596E-05 0.000365552
CIGS
0.5
Recycle Truck, 16t Truck, 16t
0.5 0.5 0.5
grams grams grams grams grams
0.0011 0 0.0011 0.0011 0.0011
N/A N/A N/A 389 2680
141 per lb 0.21 per lb 0.37 per lb 0.31 per ton-mile 0.31 per ton-mile
0.1551 0 0.000407 6.63245E-05 0.00045694
4 4
grams grams grams grams grams
0.0088 0.0088 0 0.0088 0.0088
N/A N/A N/A 389 2680
5.3 per lb 0.72 per lb 0.37 per lb 0.31 per ton-mile 0.31 per ton-mile
0.04664 0.006336 0 0.000530596 0.00365552
4 4
8
Solar Panel Holder
Material Process End Of Life Transport Transport
ABS Sec Injection Landfill Truck, 16t Truck, 16t
4 4 4 4 4
grams grams grams grams grams
0.0088 0.0088 0.0088 0.0088 0.0088
N/A N/A N/A 389 2680
2.4 per lb 0.72 per lb 0.35 per lb 0.31 per ton-mile 0.31 per ton-mile
0.02112 0.006336 0.00308 0.000530596 0.00365552
9
Main Body
Material Process End Of Life Transport Transport
Abs Sec Injection Landfill Truck, 16t Truck, 16t
10 10 10 10 10
grams grams grams grams grams
0.022 0.022 0.022 0.022 0.022
N/A N/A N/A 389 2680
1.3 per lb 1.3 per lb 1.3 per lb 1.3 per ton-mile 1.3 per ton-mile
0.0286 0.0286 0.0286 0.0055627 0.038324
10
Grip Portion
Material Process End Of Life Transport Transport
Abs Sec Injection Landfill Truck, 16t Truck, 16t
7 7 7 7 7
grams grams grams grams grams
0.0154 0.0154 0.0154 0.0154 0.0154
N/A N/A N/A 389 2680
1.3 per lb 1.3 per lb 1.3 per lb 1.3 per ton-mile 1.3 per ton-mile
0.02002 0.02002 0.02002 0.00389389 0.0268268
11
Battery Slide Cover
Material Process End Of Life Transport Transport
Abs Sec Injection Landfill Truck, 16t Truck, 16t
3 3 3 3 3
grams grams grams grams grams
0.0066 0.0066 0.0066 0.0066 0.0066
N/A N/A N/A 389 2680
1.3 per lb 1.3 per lb 1.3 per lb 1.3 per ton-mile 1.3 per ton-mile
0.00858 0.00858 0.00858 0.00166881 0.0114972
Material Process End Of Life Transport Transport
PC Injection Landfill Truck, 16t Truck, 16t
2.56 2.56 2.56 2.56 2.56
grams grams grams grams grams
0.005632 0.005632 0.005632 0.005632 0.005632
N/A N/A N/A 389 2680
3.7 per lb 0.72 per lb 0.61 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0208384 0.00405504 0.00343552 0.000339581 0.002339533
Material Process End Of Life Transport Transport
Aluminum Sec Sheet Rolling Recycle Truck, 16t Truck, 16t
12 12 12 12
grams grams grams grams grams
0.0264 0.0264 0 0.0264 0.0264
N/A N/A N/A 389 2680
0.55 per lb 0.38 per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01452 0.010032 0 0.001591788 0.01096656
Material Process End Of Life Transport Transport
LED
grams grams grams grams grams
0.00363 0.00363 0.00363 0.00363 0.00363
N/A N/A N/A 389 2680
160
Landfill (circuit boards) Truck, 16t Truck, 16t
1.65 1.65 1.65 1.65 1.65
0.5808 0 0.013068 0.000218871 0.001507902
Material Led Wire Leads PVC Jacketed Cu
0.41
grams
0.000902
N/A
12
13
14
15
Lens
Main Heatsink
LED
LED Wire Leads
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile 140
per lb
0.12628
Part OPI Totals
Sum of Impacts
16
17
LED PCB (SMD)
18650 Lithium Battery
0.052447703
0.001208106
0.030202645
0.020480339
18
19
20
Battery PCB (SMD)
USB PCB (SMD)
Process End Of Life Landfill (Circuity) Transport Truck, 16t Transport Truck, 16t
0.41 0.41 0.41 0.41
grams grams grams grams
0.000902 0.000902 0.000902 0.000902
N/A N/A 389 2680
Material Process End Of Life Transport Transport
3.27 3.27 3.27 3.27 3.27
grams grams grams grams grams
0.007194 0.007194 0.007194 0.007194 0.007194
N/A N/A N/A 389 2680
42.12 42.12 42.12 42.12 42.12
grams grams grams grams grams
0.092664 0.092664 0.092664 0.092664 0.092664
N/A N/A N/A 389 2680
0.38 0.38 0.38 0.38 0.38
grams grams grams grams grams
0.000836 0.000836 0.000836 0.000836 0.000836
N/A N/A N/A 389 2680
1.63 1.63 1.63 1.63 1.63
grams grams grams grams grams
0.003586 0.003586 0.003586 0.003586 0.003586
N/A N/A N/A 389 2680
1.7 1.7 1.7 1.7 1.7
grams grams grams grams grams
0.00374 0.00374 0.00374 0.00374 0.00374
N/A N/A N/A 389 2680
2 2 2 2 2
grams grams grams grams grams
0.0044 0.0044 0.0044 0.0044 0.0044
0.44 0.44 0.44 0.44 0.44
grams grams grams grams grams
Material Process End Of Life Transport Transport Material Process End Of Life Transport Transport Material Process End Of Life Transport Transport
PCB SMD ROHS Landfill Truck, 16t Truck, 16t Lithium Battery Recycle (Law requires Haz disp) Truck, 16t Truck, 16t PCB SMD ROHS Landfill Truck, 16t Truck, 16t PCB SMD ROHS Landfill Truck, 16t Truck, 16t
USB Plug Component of data cable
Material Process End Of Life Transport Transport
Landfill Truck, 16t Truck, 16t
Steel + Plastic
0.61149 0 0.0258984 0.000433762 0.002988388
13
1.204632 0 0 0.005587176 0.038492626
85
0.07106 0 0.0030096 5.04066E-05 0.000347274
85
0.30481 0 0.0129096 0.000216218 0.001489624
0.036
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.00013464 0 0.013464 0.000225503 0.001553596
N/A N/A N/A 389 2680
3.3 per lb 0.72 per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0.01452 0.003168 0.01584 0.000265298 0.00182776
0.000968 0.000968 0.000968 0.000968 0.000968
N/A N/A N/A 389 2680
140 1.6
per lb per lb per lb 0.31 per ton-mile 0.31 per ton-mile
0.13552 0.0015488 0 5.83656E-05 0.000402107
13 per lb 0.56 per lb 0.51 per lb 0.31 per ton-mile 0.31 per ton-mile
0.006292 0.00027104 0.00024684 2.91828E-05 0.000201054
21
Battery Spring Contacts
Material Process End Of Life Transport Transport
Steel Low Alloy sec Sheet Rolling Landfill Truck, 16t Truck, 16t
0.156030265
22
Battery Leads with Coupler
Material Process End Of Life Transport Transport
PVC jacketed copper wire Copper Wire Drawing Landfill Truck, 16t Truck, 16t
0.057162116
23
Heatsink Screw
Material Process End Of Life Transport Transport
Stainless x2 (.11 factored) Steel Cold Forging Landfill Truck, 16t Truck, 16t
0.22 0.22 0.22 0.22 0.22
grams grams grams grams grams
0.000484 0.000484 0.000484 0.000484 0.000484
N/A N/A N/A 389 2680
0.034722116
24
Thermal Grease
Material Process End Of Life Transport Transport
Silicone Oil + Ceramic Unknown Landfill Truck, 16t Truck, 16t
0.09 0.09 0.09 0.09 0.09
grams grams grams grams grams
0.000198 0.000198 0.000198 0.000198 0.000198
N/A N/A N/A 389 2680
25
Electical Use Reduced by 1/3 from PV panel
Material US Energy Low Voltage Process End Of Life Transport Transport
8.205
grams grams grams grams grams
8.205 0 0 0 0
N/A N/A N/A 389 2680
0.1296867
0.09078069
0.031008074
per lb per lb per lb 0.31 per ton-mile 0.31 per ton-mile per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
13
per lb per lb 0.39 per lb 0.31 per ton-mile 0.31 per ton-mile
0.002574 0 0.00007722 1.19384E-05 8.22492E-05
1.1
9.0255 0 0 0 0
per lb per lb per lb 0.31 per ton-mile 0.31 per ton-mile
Paper Box Package
Material Process End Of Life Transport Transport
Paper Pulp Landfill Truck, 16t Truck, 16t
20 20 20 20 20
Total Impact: ~12.99 Impact / Hour: ~0.009
grams grams grams grams grams
0.044 0.044 0.044 0.044 0.044
N/A N/A N/A 389 2680
0.7
per lb per lb 0.36 per lb 0.31 per ton-mile 0.31 per ton-mile
0.0308 0 0.01584 0.00265298 0.0182776
Solar + Single Battery Replacement
WE DID IT!
Total Impact / Lifetime Materials 12.49948 Processes 0.109553 End of Life 0.180748 Transportation 0.182181
0.037110348
0.595594773
0.129956277
Original product: Total Impact: ~21.047 Impact / Hour: ~0.0211
Lifetime hours Wear-out Life Hours used per year Impact /Hour
The Build
0.64081055
1.248711801
0.074467281
0.319425442
0.015377739
0.035621058
0.137529273
0.007040116
0.002745408
9.0255
Packaging 20
0.03890601
per lb per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
0 0.0032472 5.43861E-05 0.000374691
85
0.012800212
per lb 3.6 per lb 0.31 per ton-mile 0.31 per ton-mile
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.
0.06757058
12.9929
12.971965 1300 520 0.00999454
Timothy Harris DSID 130
Page Title
A tool from acrylic was built to create the masters that the silicone bands would be cast into.
The Build
Initially I planned to use clay, but it was so cold and the clay was too firm 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.
Timothy Harris DSID 130
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 fluid 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 modification 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 130
Page Title
A block of modulan was squared up and a groove to accommodate the solar panel on top was routed in.
The Build
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.
Timothy Harris DSID 130
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 130
soleil
™ 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.
Solar Rechargeable Bicycle Headlight
Re-power with Sunlight
Recharge with USB when it’s dark
Up to 16hrs* runtime with S m a r t S t o p Te c h n o l o g y
Weather resistant to keep shining when things get slick 6 Different light intensities for all conditions Engineered To Shine Timothy Harris DSID 130
Timothy Harris DSID 130
Packaging
The product is firmly held inside the package preventing damage during shipping. As well, the exterior and interior surfaces are available for branding.
*Enlarged to show texture
The pulp packaging allows it to stand alone or be hung from standard retail hangers Timothy Harris DSID 130
Timothy Harris DSID 130
Key improvements and Innovations: SmartStop Technology 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.
Flexible Solar Panel Integration By integrating high-performance flexible 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.
1. Innovation
Serve needs provided by associated products
2. Reduced Material Impacts
Integrated Solar Panel generates greater than 30% of the products electrical requirement under heavy use.
Use recycled or reclaimed materials
3. Manufacturing Innovation
The flexible panel also functions as the mode selector.
Minimize Number of Components
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 energy
6. System Longevity
Design for maintenance and easy repair
7. Transitional Systems
Design Upgradeable Products
A quick disconnect system improves security and encourages offbicycle use
Off-Bicycle Behavior Change If you own a bicycle headlamp, then night time vision is important and it will not be the only flashlight you own. A quick disconnect system encourages taking the flashlight off the bicycle and into the house for security, use, as well as bringing it out of dark storage to increase charge time.
User Serviceable Battery 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 Timothy Harris DSID 130