"Design with Biomaterials" - Green Design

"Design with Biomaterials" - Green Design
Ernst-König Straße-2
06108 Halle/ Saale
Tel.:+49(0)345-775158040
Fax:+49(0)345-775158001
http://www.mehrwerkdesignlabor.de
Welcome to mehrwerk designlabor's presentation
"Design with Biomaterials".Our presentation is divided
in three parts, a short theoretical prelude, then, as
second, we would like to introduce self-developed
products based on biomaterials and as third you'll see
some demands on the design with biomaterials for
sucessful products.
mehrwerk designlabor, mehrwerk.net, design-coop
Institute
Fraunhofer IWM Halle
HKD Burg Giebichenstein
Prof. F. Meinel
Enrico Wilde
Studentenprojekte
FH Zwickau
Gestalter
mehrwerk designlabor
Dracosa GmbH
SWAP
Hersteller
Gorilla Cases Berlin
Vertrieb
Quipso
Hemp 2 Use
Blatand
Jacob Winter GmbH
Powerslide
Deutsche Bahn
Kunde
Here we see the background of our work. We
understand mehrwerk hereby as mediator between
the two poles research and sales. Designing or
translating the positive results of research into lively
products. Most manufacturers now have recognized
the signs of time and want to expand their product
range to more climate-friendly products. B.t.w. for
developers often a granular already is a finished product.
As designers we need to understand new materials
which includes the material properties, the entire
process chain and the processing of materials. Structural
improvements by lightweight constructions, like optimal
use of the material properties, are important here as
well as the image a product carries itself. ultimately
the producer, the designer and the developer go likely
with a successful, because convincing product.
Verbundwerkstoffe
Armierungskomponente
• Stahl
• Technische und natürliche Fasern
• Gewebe
• Pflanzenbestandteile
• ...
Matrixmaterial/ Kleber
• Beton
• Thermoplaste
• Duroplaste
• Stärke
• Kautschuk
• ...
Stahlarmierung im Beton
Here we see a composite material made of concrete
and steel, as used in construction. Good connection
of the stiffness of the steel associated with the hardness
of the concrete, so you get a mix of properties. Which
on the surface of this foto doesn't look good because
the fiber-matrix adhesion at this point is insufficient.
The reinforcing components can now be replaced by
technical materials such as glass or carbon fiber, the
adhesive component is then shifted direction epoxy or
polyester. If we want to make a positive environmental
balance and less waste problem, we shift the
components more in the direction of the green materials,
like natural fibers and bio-resins.
Verbundwerkstoffe
Attraktivität & Akzeptanz
Unsichtbare Unterkonstruktion
Türinnenverkleidung aus einem naturfaserverstärkten
Verbundwerkstoff DLR
PKW-Interieur
Besides the know-how about the components and the
properties of the materials also the, let's say, identity
of the material is important. Important decision criterion,
in addition to the price, is the quality and the appearance
of the product. If I now say that in a modern car in the
interior the use of renewable materials is bigger than
20%, one could wonder where the course is to be. The
reason is that big an most parts lay behind the cladding,
hidden very good. So we are working bringing the
biomaterials to the surface.
Überblick Fertigungsverfahren
Here we see industry's main manufacturing methods
for the production of products in which biomaterials
come into play. Most of them can be simulated in the
own worhshop for the design process and the prototype
building. It is mostly hard work, but worth the effort.
On the left side we see the fiber winding pultrusion.
next, the press-forming of parts and panels. As fourth
we see the extrusion, where a hot mass is pressed
through a pattern and the injection molding, here to
see at the example of connectors for furniture made
from hemp fiber and lignin. As the penultimate the
pressing of insulation panels and finally the vacuum
method, used for complex composite parts with high
attributes as leightweight and performance.
Lounge-Chair: Anspruch
• Sparsamer Materialumgang
• Natürliche Werkstoffe
• Leichtgewichtigkeit
• Strukturfestigkeit und Hochwertigkeit durch Naturfaser
CO2-neutral
Welcome to the second part, the presentation of the
developed products. We start with the lounge chair,
the last example of the processing methods. Demands
were, besides seating comfort, economical use of
material, use of natural materials, lightweight and
strength. According to a modern bio-image, far of the
bio-image from the 80s, the lounge chair emphasizes
the efficiency of the materials used.
Lounge-Chair: Fertigungstechnologie Vakuum-, RTM-Verfahren
Here we see a sketch of the processing of the lounge
chair, the vakuum-laminating method. Hereby fabric,
soaked with a matrix material, is placed in a mold,
sealed with a thin foil and evacuated, which creates a
pressure under which the material hardens then. The
excess resin is collected in a reservoir before the
vacuum pump sucks it in.
Lounge-Chair: Materialien/ FEM-Berechnung/ Schlagzähigkeit
Hanffasergewebe
Feigenbaumrinde
Papier/ Pappe
Naturseide
Natives Leinölepoxidharz
Lagenaufbau
The materials of the lounge chair are the following:
fabric made from hemp fiber, the bark from the fig tree,
called in hereinafter by its trade name 'bark cloth', or
natural silk on a different model, paper honeycomb in
the inner and an epoxy matrix from linseed oil. On the
other side as well, making it a very solid sandwich
structure.
= Leichtgewichtigkeit
= natürliche Werkstoffe
Lounge-Chair: Abwicklung
Verlustfreie Fertigung
= sparsamer Materialumgang
Abwicklung und Modell von "AufJedenFalz"
The geometry of the chair is due to a rectangle when
flattened. Fabric can be used as it comes from the roll,
no sclicing and no cutting is necessary. The chair is
based on a form of origami principle. So the material
losses are minimized. This geometry, combined with
the sandwich construction, gives great stability to the
lounge chair.
Lounge-Chair: Werkstatteinblick
Fertigung eines Prototypen im Vakuumverfahren
Here you can see us by attaching the vacuum foil on
the soaked fabric placed on the mold. Left picture
shows the hardening under the already evacuated thin
foil which is pressing the layers against the mold.
Lounge Chair: Details
haptisch
sandwich
leicht
= textile Gestaltung der Armierung
Here you see details from the first prototype, the tactile
surface, the visibility of the sandwich structure on the
outer edge and the leightweight, a total of 5kg for more
than a 120kg human.
Lounge-Chair: Modelle
Here in picture you see the result of the second
prototype with textile designed and woven layer of
natural silk. The silk printing was clearly applied before
the production process, as the layer of natural silk was
still flat.
Lounge-Chair: Bedruckbar, Konfektionierbar...
Textile Anmutung, planare Gestaltung, dreidimensionale Anwendung
bosozoku-style
Here are the fine details of the second prototype. On
the front we have a layer of natural silk, on the back
bark cloth. Both gives a good strenght to the chair and
can be designed, in opposite to glass and carbon fibre,
with, for example, silk printing techniques.
kantig
silkappeal
Extrusoregalsystem: Anspruch
• Herstellbarkeit
• Nutzerfreundlichkeit
• Natürliche Werkstoffe
• Unsichtbarkeit der Verbindungselemente
• Oberflächenvariationen
keine Substitution von weniger komplexen Werkstoffen
Transportierbarkeit, leicht Aufzubauen, Erweiterbarkeit
CO2-neutral
Second example in the product category is the extrusion
shelf system, called Extruso. It is a collaboration with
the Fraunhofer Institute for material mechanics.
Fraunhofer here is responsible for the development of
compounds and the hollow structure of the panels. It
is a recipe from wood plastic composites, thus consist
of about 70% wood and 30% plastic. Demands on the
Extruso shelf were the good industrial manufacturability,
the user-friendliness, use of natural materials, various
surface variations and the non-visibility of the
connectors.
Extrusoregalsystem: Fertigungsverfahren
At the extrusion process a hot and pasty compound is
pressed through a pattern and cooled slowly on a
certain bending range. The cavities are also created
by the tool spikes in the inner.
Extrusoregalsystem: Extruder und Richtstrecke
Jurgen Bey, "Gardening Bench"
Extruder WPC-Hohlkammerprofilplatten, Fraunhofer IWM
Here as an example in the picture top left the utopia
of completely green extrusion by the Danish designer
Jürgen Bey, which uses easily garden waste for new
and good looking furniture. In reality the essential
machinery seems a lot more martial. But very nice to
look at the pattern tool and the bending range.
Extrusoregalsystem: Querschnitt einer Hohlkammerplatte
Design mit Löchern
Querschnitt einer extrudierten Platte
Strukturleichtbau
Hohlkammerprofil
Oberfläche
Here we see a cross section of the extruded panel. As
you can see it is quite hollow. Used in our shelf system,
it ensures not only for structural lightweight, but also
for the connection of the panels themselves.
Zusatzfunktion
Verbindung
Elektrifizierung
Klimatisierung
Beleuchtung
...
Extrusoregalsystem: Verbindungselemente
Verbindungselemente semantisch und funktional
For the connection of these panels we use a special
designed universal connector that can assemble with
his fellows to all situations that occur in the construction
kit. As material also hempfibre reinforced plastic is
used. Currently the mold for the connectors is getting
produced, there will be a small series of our shelf
system. From the outside the connectors are, hardly
visible, spread with a chip and get anchored in the
hollow sections. From the outside it looks like this.
Here in the photo you see a very light mixture of light
wood and the spreading chips.
Extrusoregalsystem: Transportierbarkeit
Prototyp des Extrusoregals findet im kleinsten Transportmittel Platz
A relatively large prototype of the shelf system you see
here transported in the trunk of a VW Lupo. Of course
the connection is reversible.
Extrusoregalsystem: Funktionsintegration
Visualisierung Regalsystem im Büro
And so imagined and visualized the Extruso could look
in an office. By bracing the connector into the hollow
sections, the back wall bracing gets obsolete. Different
WPC recipes provide color gradations. The Extruso
shelf system can be scaled, due to the modular principle,
in any broad or height, also subsequently.
Extrusoregalsystem: Oberflächenvarianzen...
Beispiel WPC-Spritzguss bei hoher Verfüllung mit Holz
A final interesting aspect of designing biomaterials is
the handling concerning the apperance and the natural
variances of the material. Biomaterials are by nature
suspended, even more stronger than their petro
chemical pendants, to natural fluctuations of course.
Here we see a box made of injection-molded WPC.
Interesting here is the surface structure, which develops
every time a little different. If we mean to cultivate such
accidents in industrial products, each product will carry
a personal note and thereby getting unique.
Produkte/ Accessoires
I-Phone-Cases
Laptopcases & Gehäuse
Spritzschutz - Schmutzfink
Messergriff
A few more examples are the mudguards, cases for
laptop or i-phone and the handle of this knife, made
from natural materials. Here we have driven the
individualization very far. The colors and patterns arise
by chance in the surface and emerge directly from the
casting process. Blade and clamp are fitted in the same
time and joined seamlessly.
Mobilität
Formenbau und Herstellung
Because 'biomaterial' is sometimes mistaken with 'biodegradable', we have produced this tank for a racing
motorcycle. It consists of hemp fibre fabric and linseed
epoxy, weighs just under 2kg, slightly lighter than a
thin aluminum tank and has to be extremely resistant
inside and out. External mechanical influences come
NFK-Renntank im Einsatz
in the form of shocks or punches, inside it houses the
most aggressive chemical substance, which can be
purchased legally: petrol without lead. A good proof,
that biomaterials perform a lot.
Forschung und Entwicklung
Naturfaserverstärkte Karosserie und Chassis des Zero07 des Teams Eco-Emotion
This development is a three-wheeled racer for the shell
eco-marathon from team eco-emotion. A lightweight,
made from 50% raw materials, it weighs, just like the
driver, about 50 kg. It is used as a long distance
endurance vehicle. A very beautiful example for
transportation engineering in which biomaterials just
do not have to hide since they can be very attractive
on the surface.
Mehrwert
• Bekannte Technologien
• Leichtbau und Materialeffizienz
• Funktionsintegration
• Transparente Fertigungmethoden
• Individualität im Serienprodukt
Minimierung des Energieaufwandes bei der Herstellung, beim Transport
Bauteile mit Mehrfachnutzen
Ablesbare Prozesse
---> Ziel: Höhere Akzeptanz von Biowerkstoffen
Preisliche Unabhängigkeit
As biomaterials are still slightly more expensive, in the
designing process we have to multiply functions and
with this the value of the object. It is not about to
substitute a (in producting sense) low complex material,
such as wood, by a complex natural composite. When
biomaterials come in range for use we have to make
an effort-and-benefit-calculation. more benefit we gain
through:
- Use of known and existing manufacturing technologies
- Lightweight constructions and material efficiency
- Functional integration
- Transparent production methods
- And at least individuality
Vielen Dank für die Aufmerksamkeit
Ernst-König Straße-2
06108 Halle/ Saale
Tel.:+49(0)345-775158040
Fax:+49(0)345-775158001
http://www.mehrwerkdesignlabor.de