ReThink, the first R in Circular Economy

ReThink, the first R in the 7R model.

Welcome to the first newsletter in our new series about true circular design, engineering and manufacturing (The Circular Economy). This series will elaborate around the future of sustainable design with the use of the most powerful software tools, platforms and machines available for designers, engineers and product developers. The author Stefan Larsson, worked with 3D and computer aided design since 1987. The series is focused on sustainability, circular economy and the use of design software and additive manufacturing.

Rethinking product design and shift focus into a fully circular and sustainable product.

We will start at the top, with R1 and RETHINK! Much of our new designs today need to take the whole lifecycle in consideration. Creating something new that looks amazing, satisfy the needs of its users and owners as well as being functional in micro and macro perspective. what they say about good design, "it is all in the details".... but that was the past, today the needs to create a smarter product, one that can be fully circular from cradle to grave, for that we need a system macro approach using technology like data platforms, passive or active IoT and software tools.

So let's dig into the topic and this first episode is about Rethinking the design, the product, the details and high level systematic stuff. Rethinking the concepts itself starts with the raw sketch and concepts of the design. Early on considerations have to be taken into account what materials that are available, what functionality it should bring and how it should enable itself in a circular economy. Designing today is very complex and often huge teams with different skillsets are needed to bring a full product to life, but the Rethink lies in the early phase. Correcting core values of design is very hard to do late in the process, the earlier the better. Finding an unbroken flow moving step by step through iterations, scale and function is one way we work that fits our circular design approach.

Depending on what is to be designed, there are obviously different challenges. In my opinion, the software tools has already the upper hand on us, by using simulation software, measurement tools, data and AI, much of the hard challenges can be assisted by these tools and fewer people can do much more than ever before. Think different and Think about cause and effects in short and long perspective. Designing products that can be repaired and refurbished is the future of consumers choice. You company might not like it, but as the planets survival and the environment is in focus more today than ever, these things need to come into play. How do you design and rethink your product to enable it to be fixed if broken and how do you build a system for that in a larger perspective on a longer time of scale.

Today and even more tomorrow, it is not enough as a product design only to focus on aesthetics, forms, shapes, function and materials. Most products will need to be smartly assembled and disassembled. Some parts need to be exchanged as time goes by and service staff needs to find ways to do the exchange. The materials chosen for the production, is it recycled materials and is that a solid waste stream? How will it be manufactured? will the production engineering model differ from my design intent model? how much of the original design is modified and value engineered out. My take on this, is to use small and dynamic teams, working in a single software environment as much as possible, and use 3D printing or additive manufacturing for every part of the evolving process, even considering using it for production.

For many product designers and developers it will be tough future. More advanced tools will do more for less, if you know how to use the tools, that is... Complexity in the 3D models will also add math, variables, scripting, generative design and production model knowledge. We believe that for true circular design to happen and support the 7R from cradle to grave a couple of things must be true.

• Design, simulation, engineering and product development teams need to be small and agile. Allow for mistakes and allow for developing many prototypes both internal a small pre-series for field test.
• Dare to challenge everything in your own processes, find new ways, new methods, new materials and don't hold back if it makes your product more sustainable in the long run.
• Make things that last, sustainability is best when products don't break, when they last from generation to generation
• Think and Rethink the whole cradle to grave, all 7R's in the early design phase, how will it be supported.
• Use recycled materials as long as it is feasible and allow for local distributed manufacturing if possible.

• Use lifecycle platforms like whatt.io and integrate NFC tag inside your design and use it to support the product information and knowledge over the lifespan of the product. It is very hard to find information when you need it and only with correct information can users recycle, refurbish, reuse and repair. Help foster and support a circular economy. Thinking circular on the systematic level means being smart about how to distribute product data and knowledge straight to the users and other stakeholders, this is covered with a passive IoT solution as whatt.io
• Dare to challenge the status quo, challenge every inch of your own designs and processes, test, measure, evaluate and make mistakes. Quick fixes, bad design, low quality is the worst parameters in circular economy since your product will break easily and if it is used only once and in combination that it can't be repaired and maybe not recycled, it is really bad for our environment.
• LCA, do it, to do good, not just an EPD for the marketing department. Use tools and calculations to find the lowest carbon and emission footprint possible and be proud of it. Do not make the LCA for others, make it for yourself and do your best in the design to be Carbon Neutral. Find ways to offset, add minerals in your material that comes from sucking up Co2 in our atmosphere, use locally produced materials from recycled sources. Use industrial or ocean waste instead of virgin. There is so many ways to be better.
• ReThink, the most important first step in the circle of product life, this is what will have the biggest impact and will have consequences down the line...
• Hope you enjoy'd and next episode will continue with R2 - Reduce, still from the perspective of product development and manufacturing in a circular economy...