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Introduction to Industrial Design

Process of Industrial Design


Aesthetics
Human Factor Design
Design for serviceability
Design for Environment (DFE)
Product Useful Life

Prof. Jacek Uziak


Industrial design, also called product design, is
concerned with the visual appearance of the
product and the way it interfaces with the
customer. (Pahl & Baits)

The terminology is not very precise.


For long product design has dealt mainly with the function
of the design.
However, in todays highly competitive market,
performance alone may not be sufficient to sell a product.
The need to tailor the design for aesthetics and human
usability has been appreciated for many years for customer
products.
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Industrial designers work from outside in.
They start with a concept of a complete product as it would be used
by a customer and then work back into details to make the concept
work.

Industrial designers often work in independent consulting


companies, although large design companies may afford to have
their own industrial designers: motorbikes, cars, houses, etc.

It is important to have the industrial designers involved at the


beginning of a design project, for the sake of developing proper
concept at an early stage, rather than to miss that opportunity.

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PROCESS OF INDUSTRIAL DESIGN
As engineers follow an established design procedure to generate
and evaluate concepts for the technical functioning of a product,
industrial designers follow similar procedure.

There are two typical situations in the practice:


1. The industrial designer (ID) is a part of the integrated
product-development team (IPDT) from its inception,
that is from the beginning, or

2. The Industrial designers (ID) are brought in during


embodiment design to provide styling and to ensure that the
human factors are given proper and adequate consideration.
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The first situation is preferred as the existence of industrial
designers (ID) in the IPDT can be of great benefit to engineers
(Ulrich & Eppinger )

Steps of industrial design process:


1. Determining the customer needs:
Since industrial designers (ID) are skilled in recognizing user
interaction with products they play a vital role in determining
the customer needs.
2. Product conceptualization:
ID concentrate on creating the products form & user
interfaces and they create sketches for each concept.
Closed coordination is needed to match these concepts with the
technical concepts of engineer
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3. Preliminary refinement: As the concepts are being evaluated it is
important to have three-dimensional (3D) soft models made from
plastic foam or foam-core board. The ability to touch and feel
the product helps in the concept evaluation.

4. Final concept evaluation: Before the final concept of the product


is made, it is usual to build 3D-hard models, made from metal or
plastic and painted & textured to the real product.
Hard models are technically non-functional and are made by
rapid prototyping process, but these are 3D-CAD models.
Often 3D drawings, known as renderings, are also made.
Hard models and the renderings are used frequently to get
additional customer feedback and to present the concept to the
senior management of the company for final approval.
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5. Control drawings: the industrial design process ends with
the creation of control drawings of the final concept.

Control drawings - usually document functionality, features,


sizes, colors, surface finishes, and critical dimensions.
Although they contain a lot of information about the product they
are not detailed engineering drawings, and hence are not
suitable for manufacturing of the components.
Typically the control drawings are provided to the design
engineer for reference & further consideration.

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While this is the end of the industrial design process,
some industrial design companies offer comprehensive
engineering services including:

detailed design,

selection & management of outside suppliers and

assembling the final product.

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AESTHETIC
Design for aesthetic is being given greater emphasis and is being
applied more often to technically oriented industrial products -
often this is considered as styling.
Industrial design deals with the aspects of a product that relate to
the user. (Caplan)
The First major role of industrial design is the aesthetic appeal.
o Aesthetics is a science concerning with the interaction of
product with human senses: how it looks, smells, or sounds.
o For most of the products the visual appeal is very important -
deals with shape, proportions, surface texture, colour of
elements, etc.
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Proper attention to aesthetics in design can instil a pride of
ownership and a filling of quality & prestige.
Appropriate styling elements can be used to achieve product
differentiation in a line of similar products: car models, variety of
cloths prints, etc.
Proper attention to industrial design is essential to develop and
bring to the public a corporate image about the product that the
company makes & sells.
Many companies take this to the point where they have developed
a corporate style that embodies their products i.e. in the
letterheads, souvenirs, etc.

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The second major role of industrial design is in making sure that the
product meets the user human interface, a subject called
Ergonomics or Usability.
Ergonomics deals with the user interactions with the product, making sure that
it is easy to use and maintain (March)

The industrial designer is educated as an applied artist or


architect. This is decidedly different culture than the education of
the engineer.
Engineers are trained to think in terms of technical details and
they work from inside out.
Industrial designers on the other hand work from outside in.
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Visual Aesthetics

The visual aesthetic values can be considered as a hierarchy of


human responses to visual stimuli (Lewalski)

It is known that Aesthetics relate to our emotions.

Since aesthetic emotions are spontaneous and developed


beneath our level of consciousness, they satisfy one of our
basic human needs.

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Visual Aesthetics
Hierarchy of human responses to visual stimuli:
At the bottom level of the hierarchy there is order of visual
forms, with their simplicity and clarity.
The base level of visual aesthetics hierarchy deals with the visual
neatness.
The second level of hierarchy is concerned with recognition of
functionality or utility of the design.
The highest level of visual esthetics hierarchy deals with the group
of aesthetic values derived from fashion, taste, or culture.
These are the class of values usually associated with styling.
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It was found that people react better to symmetric shapes
with closed boundaries.

Visual perception is enhanced by repetition of visual


elements related by similarity of shapes, position, or color,
known as design rhythm.

Another visual characteristics to enhance perception is


homogeneity, or standardization of shapes.

For example, we relate much more readily to a square


shape with its equal angles than to a trapezoid, and similarly
to circular shapes instead elliptical ones.

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Another way of enhancing perception is reducing the
number of design elements and clamping them into more
compact shapes.

The base level of visual aesthetics hierarchy deals with


the visual neatness.
The second level of hierarchy is concerned with
recognition of functionality or utility of the design.

Everyday life gives us an understanding of the association


between visual pattern and specific functions.

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Patterns showing a tendency towards visual separation from the base
suggest a sense of mobility or action (Lewalski)

The design of this


4-wheel-drive tractor
projects rugged power.

The grid of straight lines conveys a sense of unity.


The slight forward tilt of the vertical lines adds a perception of
forward motion.
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Patterns showing a visual separation from the base suggest a sense
of mobility or action.

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A streamline shape suggests speed, like in racing cars, high
speed trains, airplanes, fighter jets etc.

This Mazda turbocharged passenger car.

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The Honda jet plane - good example of a streamliner for high
speed flights.

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The highest level of visual esthetics hierarchy deals with the
group of aesthetic values derived from fashion, taste, or culture.
These are the class of values usually associated with styling.

There are close links between these values and the state of
available technology.

For example:
The high strength steel wires made possible the
construction of suspension bridges & TV towers.

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The availability of steel beams and reinforced concrete
columns made possible the construction of skyscrapers,
dams, large industrial buildings, oil platforms, wind-mill
electric generators & the like.

A strong driver of prevailing visual taste has been the


influence of people in position of power & wealth. In todays
society this is most likely to be the influence of the media
stars.

Another strong influence in the visual taste of people is the


human need and the search for new discoveries, and
technological developments.
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Symmetrical shapes with broad bases suggest inertness
and stability.

The following famous towers in the world are appropriate


examples:

Eiffel tower in Paris, France (325m),


Ostankino TV tower in Moscow, Russia (538m),
The twin-towers in Kuala Lumpur, Malaysia (625 m)
The highest tower in the world is Burj Dubai in the
United Arab Emirates (827 m).

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Eiffel tower in Paris, France (325m) - 1889
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Burj Khalifa ("Khalifa Tower") -
known as Burj Dubai
Dubai, United Arab Emirates,
The tallest man-made structure in the
world
829.8 m - 2010

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HUMAN FACTORS DESIGN
Human Factors Engineering or Ergonomics - deals with
the study of the interaction between people and the products
and systems, in which they work or live.
Human Factors Design applies information about human
characteristics to create objects, facilities, and environment that
people use or work in.
Industrial designers have a good knowledge about human
factors design and they focus on the ease of using products,
while the engineers focus on the design of the production
systems for productivity and safety.

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Human interacts with products in four ways:
1. As an occupant of the work space (cab or chair),
2. As a power source (usually muscle power),
3. As a sensor, looking for a warning light or sound,
4. Acting as a controller of the machine.

Products that score high marks in human factors and safety are
regarded as quality products, since they work well with the user.

Table provides correspondence between human factors characteristic &


product performance.

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Creating a User-Friendly Design (UFD)
There are several approaches to create UFD:
1. Fit the product to the user physical attributes & knowledge
2. Simplify tasks
3. Make the controls & their functions obvious
4. Use mapping
5. Utilize constrains to prevent incorrect action
6. Provide a feedback
7. Provide good display
8. Make controls easy to handle
9. Anticipate human errors
10. Avoid heavy & extreme motions for the user
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1. Fit the product to the user physical
attributes and knowledge:

This require to gather quantitative data on the dimensions of


the human body.
These are called anthropometric data and are provided by
many sources.
Design must accommodate 95% of the human population.

Data on human-force capacity is included in the study and the


research of Biomechanics.

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User-friendly design also require to incorporate the
Normans concept which states:
The design must incorporate the general knowledge
of the majority of peoples population.

Examples:
red light means stop,
higher numbers on a dial are shown in the CW direction,
knobs, or screws are tightened when turned in CW
directions, etc.

The designer should also not presume too much knowledge &
skill by the user about the product.
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2. Simplify tasks:
Control operations should have a minimum number of
operations and should be clear and straightforward.
The learning of users must be minimal and the use of
microelectronics into the product will simplify the sequence of
operations.
The product should look simple and have a minimum number of
controls and indicators.

3. Make the controls & their functions


obvious:
The controls such as knobs, leavers, keys, etc should be placed
adjacent to the device that is controlled.
Placing keys in a line is not user-friendly as it will be difficult to
find the right one.
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4. Use mapping
Make the controls reflect, illuminate, or map the operation of the
mechanism.
The idea is to make the operation clear enough and it will not
require to refer to the stickers or operators manual.
Example: The hand brake in a car should be indicated on the dash board by a
symbol similar to a brake. When it is activated it should illuminate or flash in
red, informing the driver to release it.

5. Utilize constrains to prevent incorrect


action
Do not expect that the user is going to do correct things.
Controls should be designed to prevent any incorrect action or
make it impossible.
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6. Provide a feedback:
The product must provide the user with clear and immediate
response to any actions taken.
The feedback can be provided by a light, by a sound or
displayed information.
Example: The clicking sound and flashing dashboard light in response to the
actuated car turning signal the indicators, etc.

7. Provide good display:


The human sensing characteristics involve visual, tactile
& auditory senses.
The response of the human is based on the information
received from his senses and serve as an information about
the state of the machine and its performance.
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Basic types of visual displays and
characteristics

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Selection of the controller for a product should match the
intension of the operator with the response of the system.
Design should be such that when the person interacts with the
product there must be only one obvious and correct thing to
do.
Display should be clear, visible and large enough to be read easily
without mistakes.
Analog displays are used when quick reading is required.
They also show changing conditions.
Examples: car speedometer, tachometer providing the engine speed,
fuel meter, etc.

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8. Make controls easy to handle:
Make knobs and handles of controls of different shape and size
so as they can be distinguished easily by look and by touch.
Minimize complexity by organizing controls in groups.

Controls should not require a large force to actuate, unless they


are used by emergencies.

There are 3 strategies for placement of controls:


1. Left to right in the sequence they are used.
2. Keys to be located to the operators right hand.
3. Most commonly used controls to be placed near the
operators hand.
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9. Anticipate human errors:
Human errors are unavoidable.
The designer should not anticipate that the user is going to
read the instruction manual.
He should also expect possible errors and make the design to
minimize them.
Warning is required to prevent the user from making errors
and provide opportunity to easily correct his action.

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10. Avoid heavy & extreme motions for
the user
Twisting or long arm movements, bending & large
movement of the spine are not allowed.
Especially when the these motions are repetitive - leading to
cumulative trauma disorder.

11. Standardize:
It is important to standardize controls because it improves
the user knowledge.
Example: Placement of accelerator, brake and clutch pedals in a vehicle
are standard for all passenger cars and lories irrespective of the motion
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DESIGN FOR SERVICEABILITY

Serviceability is concerned with the ease at which the


maintenance can be performed on a product (Brall)

Many product require some form of


maintenance or service

to keep their
performance within acceptable limits.

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There are two types of maintenance:
Preventive maintenance
Breakdown maintenance
Preventive maintenance
routine service required to avoid failures, such as changing oil
and filters of an engine, greasing bearings, etc.
Breakdown maintenance
service that must be done when failure or decline in
performance has occurred.

It is important to anticipate the required service of the product


and make provisions for disassembly & assembly of the
serviced product.
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Best way to improve serviceability - reduce the need for
service by improving the component and lubricant reliability.
Reliability is the probability that a system or component will
perform without failure for a specified period of time.
Design should be made to allow quick & easy identification and
location of the failed part. The panels and covers must be easily
removed and provide good access to the failed product.
Avoid: press fits, welding, adhesive bonding, riveting & other
permanent connections.
Modular design - the answer to serviceability.
Examples: alternators, turbo, pumps, gear trains
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DESIGN FOR ENVIRONMENT (DFE)

Environment is of extreme importance

A large number of environmental problems are due to a


wrong selection of particular technologies without
adequate consideration to the environmental consequences.

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Greater concern for the environment in product design requires
strong emphases on the life-cycle design of the product,
achieved through:

a) Minimizing emissions and waste in the manufacturing


processes.
b) Analyzing all the way that the product negatively impact the
environment - polluting product is a bad product
c) Using all the possibilities of increasing the product useful
life in order to safe energy & resources needed for the
replacement product.

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Life-cycle assessment (LCA) - adopted way of assessing
effects that products & processes have on environment.
Stages of LCA:
1. Inventory analysis:
The flow of energy and materials to and from the product
during its life is determined quantitatively.
2. Impact analysis:
Consideration of all potential impacts on the environment of the
above flows.
3. Improvement analysis:
The results of the above two steps are translated into specific action
that reduces the impact of the product and the processes to the
environment.
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General approach used in LCA

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Design for Environment (DFE)
is divided into two broad categories:

o Practices involving material recycling & manufacture,

o Practices avoiding the use of/or production of hazardous


substances.

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Design for Environment (DFE)
Principles:
1. Design for material recovery and reuse
2. Design for disassembly
3. Design for product waste minimization
4. Design for waste recovery and reuse in processes
5. Design for Packaging recovery
6. Avoid the use of hazardous and undesirable materials
7. Consider the environmental hazard on production workers
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1. Design for material recovery and reuse:
Traditionally the recycling and reuse of materials is governed
by economics & special regulations.

Materials such as steel and aluminum can be collected and


reprocessed at a profit, if recycled.

Apart of economic benefits other benefits are recognized and


these are:

Saving energy, reducing pollutions & hazardous gases,


keeping nature clean, etc.

Life Cycle Assessment as a general approach to be used

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2. Design for disassembly:

Provide for easy access & removal of parts.

Avoid embedding parts of incompatible materials

Avoid the use of screws & welds but use snaps, clips, and
other means for quick disassembly.

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3. Design for product waste
minimization:
Minimize the amount of material used by avoiding
overdesign of the components.
Learn, which materials are incompatible in recycling in
order to separate & segregate them.
Keep the number of different materials to minimum to
reduce the recycling cost.
Understand, which paints, labels, adhesives can cause
contamination when recycled & avoid them.

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4. Design for waste recovery and
reuse in processes:
The waste of a product is usually a small fraction from the
waste generated by the processes that produce it
(electroplating, alloying, painting).
Consider the environmental implications in
manufacturing and selecting the processes.
Be aware of the ways of reducing process waste.

Select a material for a component taking into consideration


how it will be manufactured.

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5. Design for Packaging recovery:

Be familiar about the changes in industrial packaging that


are allowed for recovery, recycling, and reuse.
Look for different ways of redesigning shipping containers
so that they can be reused.

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6. Avoid the use of hazardous and
undesirable materials

Be familiar with the changes of government regulations


and the list of hazardous materials
Avoid the use of hazardous materials if possible.

If their use is unavoidable be aware about the safety


precautions when using them.
Use biodegradable materials if possible (e.g. plastics
instead metals, plastic bags-shopping).
Avoid the use of CFC (ChloroFluoroCarbon) refrigerant to
save the ozone layer of the atmosphere, absorbing UV.
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7. Consider the environmental
hazard on production workers
Production workers should not be put at risk by the
environmental hazards. These include:
o The harmful effects of exhaust gases and industrial
smoke,
o Exposure to very high or low temperatures, noise,
radiation, moisture, etc.
Workplace conditions should satisfy the latest government
regulations.
The overall design should consider that people are working in
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Design for noise reduction:
High levels of noise is considered a hazard.

Noise levels at the work place should not exceed 80 decibels


(e.g. the noise at airports, trains etc.).
There are two ways to reduce high levels of noise:
Design the work place so that the noise does not exceed a
preset threshold.
Insulate the source of noise by enclosing it or by using a
specially insulated foundation for the source, so as the noise
does not escape to the environment or propagate through the
ground.
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Recycling and Material Reuse
Total life cycle of materials:

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Material cycle:
Mining of minerals, pumping oil, harvesting wood and
agricultural fibers such as cotton, etc.
Processing, refining, & extracting bulk materials e.g. a
steel ingot, which is further processed into finished
engineering material such as steel sheets, profiles such as bars,
pipes, beams, etc.
Then the engineers design a product that is manufactured
from the material and the product is put into useful service.
In the process of usage the product wears out or become
obsolete, because a better product comes on the market, e.g.
The products of the digital electronics has replaced the analog
ones: that is LCD, LED TVs replaced the Tube one, etc.
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Benefits of material recycling:
Contribution to the supply of bulk materials.
Reducing the consumption of natural resources.
Reduction of the solid waste that has to be disposed of, in a
landfill, thus contaminating.

Recycling contributes to the improvement of the


environment through:
Saving energy by producing materials from recycled material rather than
from ore.
Reducing carbon emissions is appreciable.
Reducing pollutions directly, e.g. producing steel from scrap bypasses the
blast furnace and therefore the use of CO2 .

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A good alternative to recycling is remanufacturing:
Instead of disassembling the product for recycling materials the
product is restored to a new condition. This is done by
replacement of worn parts.
Some secondary materials are generated in the material
processing & the utilization cycle by using:
o Home scrap: the material is recovered from primary material
production: Cropped tops of ingots or sheared edges of sheets,
plates, bars, etc.
o Industrial scrap or new scrap is generated during the
manufacture of products: e.g. stamping scrap, bundles of turning,
or spinning, etc.
o Old scrap is scrap generated from a product that has completed
its useful life. Its also called obsolete or post consumer scrap, e.g.
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a scraped car, fridge, or any machines.
Recyclability
Refers to the ease with which a material can be recovered
from a used product.

The steps in recycling a material are:


1. Collection and transportation to the factory
2. Separation of parts (disassembly)
3. Identification of materials and sorting
4. Reprocessing of materials
5. Marketing of the final materials
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Collection
Methods include:
Curbside pickup

Buy-back centers

Resource recovery centers:

At these centers solid waste is sorted for recycling and other


waste is burnt for energy.

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Separation usually follows one of two
paths:
1. Selective dismantling
E.g. toxic materials like engine oil and lead batteries are first
removed and then given special treatment. High value materials such
as copper, gold, etc. are removed & segregated.
2. Shredding
The product is subjected to multiple high-energy impact to batter to
small irregular pieces.
Shredded material is further sorted into different materials using
special techniques such as:
o Magnetic separation
o Vibratory sieves
o Air sorting, and
o Wet flotation
o Plastics are sorted by using the principle of Raman
spectroscopy, much like a barcode scanner.
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Identification of materials, sorting and
reprocessing
After sorting, the recycled material is sold to a secondary materials
producer
o Metals are re-melted in Marten furnace - ingots
o Plastics are ground and processed into pallets
Thermoplastic polymers can only be recycled, in contrast to thermosets,
which cannot be recycled.
Usually recycled plastics can be used for less critical applications, but
today's technology allows engineering plastics to be recycled 3-4 times
losing only 5-10% of their original strength

Marketing of the final materials


Then these are send to the material stream by selling the recycled materials
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to component manufacturers.
Product useful life
The following design approaches apply in order to extend product
useful life (Magrab):

1. Design for durability:


Durability is the amount of use one can get from a product before
it breaks down and a replacement is preferred instead of repair, i.e.
mileage of a vehicle before failure of sparks; no. of hours of bearing
life, etc.

2. Design for reliability:


Reliability is the ability of the product to neither malfunction nor
to fail within specified period. Design for strength, fatigue, etc.
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3. Create an adaptive design:
A modular design is suggested in order to create improvements
of various functions of the product.
4. Repair:
Feasibility of replacing nonfunctioning component to attain the
initial performance.
5. Remanufacture:
Worn parts are restored to a new condition to achieve specified
performance.
6. Reuse:
To find an additional use for the product or its components
when is retired from its original service.
Example: Jet engines are used to extinguish fire in oil industry, navy and fuel storage
facilities. A non-warned engine or gear box component to be reused as spare parts,
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etc.
7. Recyclability:
Reprocessing of the product to recover some or all of the
materials it is made of.
This requires the product to be disassembled cost-
effectively, identify the materials and have an economic value
at the end, in excess to the cost.
8. Disposability:
All materials that are not recycled should be legally and safely
disposed of in land pits.

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