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Sustainable Electric Toothbrush
1. PROJECT
BRIEF
The purpose of this project was to
demonstrate an ability to apply
research findings from emerging
biomaterial studies to the design
and development of a feasible
product as a team, from concept to
manufacture. The following pages
illustrate the process our team
executed throughout the ten weeks
of product development.
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2. CLASS 3
CLASS 4
WEEKEND
PRESENT.
#1
CLASS 5
CLASS 6
WEEKEND
CLASS 7
CLASS 8
WEEKEND
CLASS 9
PRESENT.
#2
CLASS 10
PRESENT.
FINAL
RESEARCH:
BIOMATERIALS
RESEARCH:
CONCEPT
CONCEPT
DEVELOPMENT
CONCEPT
REFINEMENT
CAD/SKETCH REFINEMENT/
PROCESS BOOK
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3. LINCOLN NEIGER
MICHAEL NOTO
CONSTANTINO PAPATSORIS
MATERIALS:
MATERIALS:
MATERIALS:
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• Thermo-Hygro-Mechanically
Compacted Wood (THM)
• Cork Polymer Composites (CPC)
• Almond Polymer Composites (APC)
• Algae-Based Materials
• Fungus-Based Materials
• Natural Fiber Composites (NFC)
Bioplastics Based on PLA
Bioplastics Based on PHB
Bioplastics Based on TPS
Bioplastics Based on Cellulose
Bioplastics Based on Vegetable Oils
Lignin-Based Bioplastics
Algae-Based Bioplastics
Bark Cloth Materials
Maise Cob Board (MCB)
Bioplastics from Animal Sources
Acrylic Glass Derived from Sugar
Wood Polymer Composites (WPC)
Coconut-Wood Composites
Bamboo
Heat-Treated Natural Woods
RESPONSIBILITIES:
RESPONSIBILITIES:
RESPONSIBILITIES:
• Project Manager
• Process Book
• Final Sketches
• Bill of Materials
• CAD Model
• Renderings
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Properties:
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light weight
shatterproof
transparency
UV resistant
weatherproof
Applications:
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acrylic glass
protective goggles
vehicle lights
displays
Suppliers:
• currently in development
based on natural raw
materials/less energy
consumption and waste
during production than
current methods
ACRYLIC GLASS
DERIVED FROM SUGAR
A new process is in development
that employs sugar, alcohol, and
fatty acids to create a splinterless
material, as clear as glass. This
material could potentially replace
acrylic glass. Processing of this
material uses less energy and
creates less waste than current
options.
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Properties:
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high strength
durability
homogenous surface texture
airtight
thermoplastic processing
properties
• compostable
• biodegradable
• recycleable
Applications:
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furniture manufacturing
material coatings
building containers
wall panels
coffins
Suppliers:
• Duralmond®
• mastAlmond®
replaces wood with plant
waste products/raw material
grows quicker than wood/
biodegradable
ALMOND POLYMER
COMPOSITES (APC)
Made of ground almond shells and
a biodegradable resin, almond
polymer composites (APCs) can
be produced faster and easier
on account of its renewable raw
material. The almond shells are
natural by-product on farms that
produce and harvest consumer
almonds.
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Properties:
• high elasticity
• very high bending and tensile
strength
• 25% harder than oak
• susceptible to moisture
damage
Applications:
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scaffolding
furniture
construction
flooring
household goods
fashion accessories
bicycle frames
Suppliers:
• Conbam®
• Moso®
• Natural Bamboo
highly renewable material/
biodegradable/light
construction potential with
high durability and stability/
may be used as an alternative
to carbon fiber-reinforced
plastics or aluminum
BAMBOO
Known for its rapid growth and
strength:weight ratio, Bamboo has
been used as a building material
for centuries.The canes are smoked
and heat-treated before use. Its
hollow interior allows for the
material to be flexible and light.
When used outdoors, bamboo
must be protected from moisture,
insects, and fungal decay.
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Properties:
• beige to dark brown
• individually adjustable
qualities
• waterproof
• opaque
• elastic
• tearproof
Applications:
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light canopies
partitions
lampshades
shoe design
fashion accessories
Suppliers:
• Bark Bloth®
• Barktex®
based on renewable raw
materials/harvested
through small-scale farming
in developing regions/
biodegradable
BARK CLOTH
MATERIALS
Bark cloth is harvested from the additives used, the bark cloth can
bark of the Mutubu fig tree with the employ different characteristics.
help of Ugandan farmers. It is then
sealed with additives to make it
wear-resistant. Depending on the
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Properties:
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stable under water
biodegradable
recycleable
mold & bud resistant
low density
flame retardant
Applications:
• packaging
• insulation
• items in car interiors
Suppliers:
• Algix®
• Cereplast®
• Verpackungs Zentrum®
based on highly renewable
raw materials/emits no
pollutants during processing/
can be naturally composted/
recycleable/more expensive to
produce/products are said to
maintain an algae smell
BIOPLASTICS BASED ON
ALGAE
Discovered while researching
opportunities for bio-fuels based
on algaes, algae-based bioplastics
offer
a
highly
sustainable
alternative to traditional foams
and plastics. Researchers have
produced and alginsulate foam
which could potentially replace
expanded polystyrene.
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Properties:
• styptic
• antibacterial
• soluble in water and alkaline
solutions
• impermeable to oxygen
Applications:
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filtration
wound-dressing
surgical thread
toothpaste
food packaging
wood preservative
binding & smoothing agents
for paper production
Suppliers:
• Animpol®
• Eastern Bioplastics®
• N-chitopack®
based on natural raw
materials/biodegradable/can
be poured to create a film/can
be processed into foams and
fibers
BIOPLASTICS BASED ON
ANIMAL SOURCES
Chitin, the main component in the
exoskeletons of spiders and crabs,
is extracted and produced into
chitosan. Chitin is the most notable
renewable resource from animals
sources in the production of
bioplastics. The inherent properties
of these bioplastics make it suitable
for use in medical products and
biotechnology.
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Properties:
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good mechanical properties
optical transparancy
self-polishing
good thermal resistance
normally requires a softener
for processing
Applications:
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writing utensils
umbrella handles
spectacle frames
cigarette filters
giving goggles
steering wheel covers
lampshades
toys
tool handles
Suppliers:
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AgriPlast®
Arboform®
Biograde®
Moniflex®
Tencel®
Zelfo®
based on renewable
resources/can be recycled/
mixing cellulose with other
plastics can produce unique
polymer blends/can achieve
various levels of permeability/
ideal for injection molding and
extruding
BIOPLASTICS BASED ON
CELLULOSE
Found in the cell walls of every
plant, cellulose is the most
common organic compound in
the world. Cellulose is ideally
suited to producing thermoplastic
bioplastics
for
translucent
components. The most common
bioplastics based on cellulose are
cellulose acetate (CA) and cellulose
triacetate (CTA).
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Properties:
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good mechanical properties
high degree of rigidity
brownish coloring
duroplastic qualities
Applications:
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construction materials
vehicle dashboards
buttons
toys
disposable cutlery
packaging
Suppliers:
• Biome Bioplastic®
derived from renewable raw
materials/processing qualities
are compared to that of wood/
can be welded together at
high temperatures without the
need for adhesives
BIOPLASTICS BASED ON
LIGNIN
Comprising 30% of a tree, lignin
is the second most common
biopolymer found in nature after
cellulose. Lignin is extracted from
wood shavings and fibers in a
boiling process and then combined
with products like methanol and
hydrochloric acid to form a resinlike substance, which is then made
directly into a duroplastic.
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Properties:
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similar property profile to PP
low oxygen diffusion
UV stability
biocompatibility
high fracture susceptibility
non-transparent
tensile strength
Applications:
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consumer goods
packaging
adhesives
hard rubbers
automotive industry
Suppliers:
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Biocycle®
Biomer®
Enmat®
Metabolix®
Natureplast®
Nodax®
based on renewable sources/
biodegradable/can be
processed using traditional
plastics processing/rapid
transitions from fluid to solid,
resulting in rapid processing/
will likely replace PP in coming
years
BIOPLASTICS BASED ON
POLYHYDROXYBUTRIC ACID (PHB)
PLA’s popularity is due to its
comparability to PP. The most
important
representative
in
polyhydroxyalcanoates polyester,
can be found in almost every living
organism. PHB is often mixed with
other substances to produce more
appropriate blends to negate PHB’s
high fracture susceptibility.
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Properties:
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similar property profile of PET
low permeability of gases
water-repellent surface
transparent
shiny
relatively low heat stability of
just over 60C
Applications:
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yogurt containers
food foils
geo-textiles
cosmetic injections
automotive, entertainment,
agriculture, landscaping
industries
Suppliers:
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Natureworks® Polymer
Ecovio®
Bioflex®
Ecoghr®PLA
Ingeo®
based on renewable
resources/recyclable/
compostable under certain
circumstances/ideal for
lightweight application/
manufacture produces
high CO2 emissions/
mechanical resistance and
biodegradability is dependent
on the material composition
BIOPLASTICS BASED ON
POLYLACTIC ACID (PLA)
Polylactic Acid (PLA) is often the
center of sustainability discussions
as the most popular bio crude
plastic due to its potential to
replace PET. PLA must be mixed with
aggregates through compounding
to suit specific needs. It is produced
primarily through the fermentation
of sugar syrups and starches.
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Properties:
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liquid absorption
good value for money
excellent gas barrier
energy-efficient production
Applications:
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medication capsules
packaging foils
yogurt cartons
disposable cutlery
plastic bags
coated cardboard
Suppliers:
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Biomax® TPS
BioPar®
BioplastTPS®
Sorona®
based on renewable
resources/excellent
biodegradable quality/
energy-efficient production/
must be combined with a
biodegradable polymer in
order to introduce insoluble
qualities
BIOPLASTICS BASED ON
THERMOPLASTIC STARCH
The majority (80%) of global
bioplastic production is made up of
polymers based on thermoplastic
starch. They provide good value
for money due to their ubiquity, as
they are sourced from corn, grains,
and potatoes. Thermoplastic
starch is often just one component
of plastics production.
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Properties:
• bio-based polyamides
thermoformable
additives can add new
properties
• bio-based foams
flexible
light weight
hard or soft
• bio-based resins
similar to synthetic resins
biodegradable
Applications:
• mattresses
• foams of various densities
Suppliers:
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Akromid® S
Envirez®
Lupranol®
Rubex® NaWaRo
Vestamid Terra®
based on renewable resource/
not always biodegradable/
can compete with petroleumbased polyamides/have a
more favorable CO2 footprint
than alternatives
BIOPLASTICS BASED ON
VEGETABLE OILS
Vegetable oils can provide the for technical products and resins
raw materials required to produce for fiber compounds or foams.
bioplastics, enabling the bio-based
production of polyamides
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Properties:
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minimal shrinkage & swelling
very hard, dense outer layer
no growth rings
dimensional stability
high bending strength
Applications:
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furniture
parquet flooring
wall panels
lamps
vases
dishes
fashion accessories
Suppliers:
• Ekobe®
• Kokoshout®
based on natural raw
materials/biodegradable/
conventional timber
processing technologies are
applicable/oils can be used for
intense coloring
COCONUT-WOOD
COMPOSITES
Often used in place of exotic woods, Coconut wood composites have a
coconut wood has no annual rings, 12-18 mm MDF-core, to which the
rendering the dense, outer five harvested coconut wood is applied.
centimeters of the trunk the most
useful in composite production.
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Properties:
• unique tactile qualities
• adjustable flexibility
• thermoplastic processing
qualities
• rot-resistant
• water-impermeable
• noise and vibration
absorption
Applications:
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medical devices
sport products
orthopedic products
furniture
lamps
vases
bike handles
Suppliers:
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Amorim®
Lifecork®
Subertres®
Thermofix®
Vinnex®
based on renewable raw
materials/biodegradable/
recyclable/may employ
traditional thermoplastic and
wood processing methods
CORK POLYMER
COMPOSITES (CPC)
Cork polymer composites (CPCs)
are comprised of cork particles
suspended within a plastic matrix.
The cork particles can range in size
from .5-2mm, depending on the
required material flexibility. The
combination of these materials
creates a material impermeable to
water as well and thermoformable.
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Properties:
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durable
antibacterial
nonslip
takes pigment well
sensitive to moisture
Applications:
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flooring
tabletops
surface coverings
high hygienic rooms
Suppliers:
• Armstrong®
• Forbo®
• The Natural Abode®
based on renewable raw
materials/compostable/
production produces no waste
LINOLEUM
Originally introduced to the market
in the early 1800s, linoleum has
gained recent attention as it is
comprised from linseed oil, lime
powder, and sawdust. It is mostly
used for surfacing interiors. The
material is sensitive to moisture
and should not be used in areas
that get wet for long periods of
time.
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Properties:
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aesthetic transparency
available worldwide
flame retardant
rapid growth
Applications:
• wall panels
• building containers
Suppliers:
• unknown
based on a rapidly renewable
raw material/replaces
conventional reinforcing
fibers/decomposes when
natural resin matrix is used
MATERIALS BASED ON
ALGAE
Algae based materials are formed
through the incorporation of a
algae into a resin matrix. Over
200 types of algae are in use in
the development of algae-based
materials. Because algae does not
require a high level of maintenance
in its cultivation, good supple is
often readily available.
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Properties:
• heat insulating
• sound & shock absorbent
• compostable
Applications:
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packaging
insulation
panelling
table tops
Suppliers:
• EcoCradle®
• Ecovative®
based on a natural waste
material/energy-efficient
manufacturing process/
compostable/the growth
process takes place in the dark
MATERIALS BASED ON
FUNGUS
Fungus-based materials employ
a production method that allows
them to grow naturally. The base of
the material can be anything from
husks of rice to wheat. A fungus
is introduced, growing a network
of threads to bring the base
material together. The material is
dehydrated to stop the growing
process.
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Properties:
• low density
• high durability along axial
direction
• similar qualities to particle
board
• heat insulation
• noise absorption
Applications:
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furniture surfaces
panelling
insulation
doors
Suppliers:
• currently in development
uses agricultural
byproducts/50% lighter than
particle board/exceptional
noise absorption
MAIZE COB
BOARD (MCB)
Maize cob board employs the use is currently in development and at
of the natural waste from farms, present is confined to panelling.
corn cobs. The cobs are sliced and
sandwiched between two boards
of various materials. The material
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Properties:
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light weight
flame retardant
good mechanical strength
rapid growth
available worldwide
Applications:
• protective helmets
• molded parts for cars
Suppliers:
•
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Arbofill®
Biofiber® Wheat
Cellucomp®
Greenline®
NaBasCo®
based on renewable raw
materials/can replace
current reinforcement fibers/
lighter than current fibers/
compostable
NATURAL FIBER
COMPOSITES (NFC)
Natural fiber composites are
comprised of a combination of
fibrous materials found in nature
(hemp, flax, coconut) and a
synthetic resin. The resin allows
the material to be processed using
typical thermoplastic processing
procedures. Different combination
of materials give these composites
various properties.
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Properties:
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lower water absorption
high dimensional stability
dark coloring
fungal resistance
good acoustic properties
Applications:
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facade cladding
solid timber flooring
toys
playground equipment
decking
Suppliers:
allows local species to
replace exotic, tropical
woods/less energy consumed
in procurement/can be
processed through normal
manufacturing techniques
• Accoya®
• Admonter®
• OHT Wood®
HEAT-TREATED
NATURAL WOODS
Heat-treated
natural
woods
allow for an increased quality
of lower-grade lumber in order
to make it suitable for outdoor
use. Applying heat, pressure, and
acetic anhydride to less-durable
woods through the process of
acetylation reduces the wood’s
water absorption rate, making it
more suitable for outdoor use.
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Properties:
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high degree of elasticity
very resilient
amber color
sticky when wet
becomes brittle with age
susceptible to fungi
Applications:
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balloons
condoms
tires
rubber springs
engine mountings & seals
hoses & cable coatings
Suppliers:
• Linatex®
• Yokohama®
• Bedell Kraus®
based on renewable
materials/biodegradable/
tackiness when wet allows it
to be used as an adhesive/only
turpentine or petroleum can
dissolve it/rubber trees are
currently under attack by a
resilient fungus; scientists are
working toward an alternative
source
NATURAL
RUBBER
Natural rubber is extracted from
the sap of a rubber tree to form
a latex. It consists of natural
caoutchouc, water, and sulfur. Its
properties make it desirable for
applications requiring elasticity
(it can be stretched up to 10 times
its size) and resiliency. Natural
caoutchouc is used in 40% of all
industrial rubber production.
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Properties:
• even property distribution
• low shrinkage
• high rigidity & bending
strength
• low thermal expansion
• high resistance to moisture
Applications:
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casings for electronics
handles
furniture
outdoor ground surfaces
building components
fashion accessories
bio-urns
Suppliers:
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Fasal®
Megawood®
Kupilka®
Fibrolon®
Werzalit®
based on renewable
materials/crude, oil-free
matrix materials are
biodegradable/maximum
processing temperature
should not exceed 200C
WOOD POLYMER
COMPOSITES (WPC)
Wood
Polymer
Composites
(WPCs) are formed from wood
fibers, a plastic matrix, and
various additives. Often referred
to as ‘liquid wood’, WPCs can be
processed using most traditional
thermoplastic
processes.
Its
properties make it particularly
desirable for the manufacture of
precision components.
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Properties:
• increased rigidity
• weather resistant
• 80% less material waste
Applications:
• building materials
• wooden tubes
• heavy packaging
Suppliers:
• unknown
saves materials compared
with round wood/requires less
energy that the manufacture
of wood fibers/process can be
reversed and shaped
THERMO-HYGRO-MECHANICALLY
COMPACTED WOOD (THM)
THM is wood that has been
compacted to increase the
material’s density. In the heating
process, the wood’s biological
resistance is increased while the
cell structures remain intact.
Processing may be completed with
our without mechanical force and
his temperature steam.
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28. RESEARCH
& OPPORTUNITIES
With sustainability as our primary goal, processing of its materials and its highest
we set out to research the current context point of environmental impact occurs
of the electric toothbrush. We found that during the toothbrush’s daily use.
the electric toothbrush’s highest point of
energy consumption occurs during the
Given the nature of the course and our consumption associated with daily use,
project timeline, we chose to focus on and the facilitation of proper product
increasing the electric toothbrush’s disposal.
sustainability through our choice of
materials, the reduction of energy
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29. Energy Usage Over Product Lifecycle
Highest Point of Energy Consumption
Highest Point of Environmental Impact
Material
Production
Daily
Production
& Distribution
Use
Opportunity
Opportunity
EOL
Opportunity
Change the materials used in the production
of an electric toothbrush...
Reduce the amount of energy consumption during
the electric toothbrush’s daily use...
Provide avenues for
proper disposal...
Which materials might offer the
highest benefit in terms of resources,
recyclability, and energy consumption
during production/processing?
How might we provide a solution to the
energy loss associated with
vampire energy?
How might we
enable the user
to dispose of
their toothbrush
properly?
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PRODUCT
LIFECYCLE
Due to our design opportunities
spanning the entire length of
the electric toothbrush’s product
lifecycle, it quickly became
apparent that we must first set
out the lifecycle of our toothbrush
before focusing on its form.
Following is an explanation of
the lifecycle we set forth for our
product.
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31. Company Actions
Production
Company Actions
Distribution
Receive &
Dispose
User Actions
Purchase
Use
Charge
Separate Parts
Package & Send
Non-Recyclables
Material Disposal
Properly Dispose
Parts
Recycle
Remaining
Parts
Replace Head
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32. MATERIAL
SELECTION
Bioplastics Based on Cellulose:
We chose to use this material due
to its availability, sustainability
and recyclability.
Cork Polymer Composites:
We chose this material due to its
impermeability to water, natural
gripping texture, and absorption of
vibration.
Natural Rubber:
We chose to use this material due
to its natural tactile qualities. It is
also a more sustainable alternative
to industrial rubbers.
Acrylic Glass Derived from Sugar:
We chose this material due to its
transparant qualities. It is also a
more sustainable alternative to
traditional acrylics.
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IDEATION
With a clear understanding of our
potential materials and a vision set
forth for the lifecycle of our product,
we moved forward as a team in
ideating product form.
Through a series of sketches,
we came to a concensus on the
direction of the toothbrush’s
physical concept and aesthetics.
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CONCEPT
REFINEMENT
We continued to refine our sketches
and explore the toothbrush’s form,
taking the human factors and
industry standards into account,
until we arrived at a final concept.
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