DSM Ahead Material Sciences R&D DSM-DDW RvdB. DSM Ahead Material Sciences R&D DSM-DDW RvdB

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1 Rinus van den Berg Architectural & industrial designer DSM / MSC Conceptual Design DSM, Design & C2C Design is a seed 1 Introduction The Final Interface Design and plastics Some examples 2 DSM History, evolution and competences DSM's & Sustainability RESPECT $ 3 4 C2C & sustainability The old way...who CARES?! TAKE MAKE WASTE Pollution, dispersion, unknown, untraceable Jan Verlaan AKZO Disintegrate / dematerialise 5 6 1

2 Current concept...cradle TO GRAVE TAKE Better means less bad MAKE DFDA R5 Reach iso... ELV UP-DOWN DOWN-RECYCLE REGENERATE REUSE WEEE Rohs etc REDUCE WASTE 7 CRADLE TO CRADLE GIVE TAKE Be good instead of less bad Eliminate the concept of waste RE-MAKE Lease instead of own Rematerialise X WASTE 8 Cradle to Cradle paradigma shift. Doing the right things good C2C requires new business models Lease materials or products. More control in the overall chain. Reclaim rights. From linear to cyclic systems Author / production rights for a product *. * Also after sale the artist can claim rights on his work / product. Closing cycles B2B B2C Light for hire Seats for hire Doing the wrongs things right Performance for hire 9 10 Key C2C = knowledge of materials & transformation processes Chains of parallel and sequential gate-in / gate out modules The Final Interface Design and plastics Some examples KM

3 A "final" step in the value chain..... a human buys or start using a product. Adding value in the supply chain. A peculiar step in the material transformation process......the interface between amorph material & specific geometry. etry. Shape stores Memory Geometry is life Order requires energy Material becomes shape Lost of control $ profit 13 Morphology driven by marketing. Generating a PoD. The DNA for product development. 14 From amorph to specific......the magic moment in geometry y generation. The final interface is not straight & multi-morph The cradle starts with Design The interface between matter & market Doing good or making shit starts here! The final interface and thermodynamics Reuse, Recycling, up & down grading complex stuff! technical nutrients biological nutrients In search of control Lost of control

4 Design in a Cradle 2 Cradle context Design Heroes Design and plastics Some examples DESIGN IS BASED ON THE ATTEMPT TO FULFILL HUMAN NEEDS IN AN EVOLVING TECHNICAL AND CULTURAL CONTEXT McDonough & Braungart Design as the First Signal of Human Intention* *McDonough EQUITY people ECOLOGY planet E4 Design is a seed Embedment ECONOMY profit Creating value? for whom? Needs? Concept development needs C2C base vision An estimated 80% of a product s environmental impact is fixed in the conceptual design phase. So take early opportunities to design-out waste Design is based on generic concepts Technology is evolutionary Mechanical piano +/ B & W Colour Portable CD +/ HUMAN DESIGN Almost autonomous generic functionality / geometries occur in our technocracy based on signaling humans intentions Stereo Flat screen LCD/Plasma 3D TV 3D Beamers Holographic beamers 24 4

5 Design is evolutionary Each evolutionary change is a "new" program DNA / POD & another start from the new final interface. The effect of time on delivered usage / functionality Product embedded energy / environmental impact versus use time Product hierarchies systems, levels & boundaries. Effect of use time in LCA evaluations. It makes an apple tree or a Pine tree 25 Nissan Tama 26 Intended use and material properties Closed cycle management. Overall chain containment guarantee. In those cases where HS are required for specific functionality. Design for disassembly Components and assemblies Closing cycles B2B B2C Components monolithic monomaterial Components monolithic multi material Compatible / incompatible Assemblies mono-material multi-material Compatible / incompatible Eco-Design enables Cradle-to to-cradle Make it less complex Use recycled, recyclable, renewable materials Design for Repair Design for disassembly Use LCA In design decision making Make it more useful (Multi-use) use) Make it modular Intended use Reduce Material Variety Design for upgradeability Durable and high quality Standardization Avoid toxic and harmful Materials & chemicals Reduce size And weight Optimize Manufacturing Process Use Eco Packaging 29 Sustainable styling? Berker serie 1930 Bauhaus from bakeliet into porcelain. 30 5

6 Open systems between inner en outer......detach styling from other functions. Standardisation of interfaces and the use of modules/modularity Open systems allow open connections between components by (international) agreement. easy repair, adaptable, grow etc True for harware & software (Go Gear versus Ipod) Design for repair Elimination of interfaces.can I make it out of one part??? Mono-component Multi-component Designed for reuse in different function. bottle/bricks WOBO Heineken WOBO Bottle John Habraken 1961 Add multi functionality Collect and, up, -re or down cycle Stimulate down-re-up-cycling Upgrade / clean / sort for: 1 & 3 world raw material business in: Same functions or different functions

7 Advantages of plastics for eco product development - High efficient transformation process - Durable without corrosion protection or paint - Function integration - Reduction of investments - Reduction of weight - Wide range of surface appearances Plastic Fantastic Fantastic+ - Zero maintenance (UV degradation of some polymers) - Recyclable with minimum of energy - Up -re & -down cycling, bio degradable, combustible Unique ability of plastics Plastics can be made from Non renewable and renewable feedstock Fossil Switch grass Unique C2C ability of plastics Plastics can be a technical nutrient or they can be a biological nutrient Renewable or Bio-plastics Bio-plastics are plastics whose components come from renewable raw materials. They can be durable or degradable. Also bio based plastics needs recycling! Cleaner processes GHG savings Less energy New polymers E.g. Switch grass Water Phosphates Bio degradable plastics 3 states of degradability Bio-degradable plastics are plastics that will decompose in the natural environment and are considered safe for biological cycles. They can be made from non & - renewable feedstock. 41? 1 Toxic / eliminates growth 2 No effect / neutral ( bio-degradable) 3 Enhance growth ( Eco-effective) 42 7

8 Use tools for eco-evaluation evaluation Raw materials consumption Energy consumption Emissions Toxicity potential Risk potential Example of a ecological fingerprint ( BASF) Proper data. Reach, Material data bases, Campus etc. Life Cycle Assessment. LCA methods GHG footprint analysis. Proper systems analysis. Boundaries. Design for disassembly. CAE simulations. Material / production cost, economic values DSM LCA Competence Center The Final Interface Design and plastics Some examples Global wide footprint analysis for all products DSM & C2C Evaluation / fit current strategy DSM Engineering Plastics Materials Platform Using the Cradle to Cradle materials assessment framework, the suitability of materials for the biological or technical cycle is evaluated DSM RE-CAP process PA 6 "endless" technical nutrient cycle. DSM Akulon PA 6 & Arnitel TPE in Herman Miller ler C2C office seats. 47 Chair features common materials applied in original ways such as the elastomeric seat suspension and molded polymer back that are used instead of foam and fabric. The relationship between materials and technology was optimized to achieve maximum performance with minimal materials 48 8

9 Upgrading properties of recycled plastics with chain extenders. ALLINCO ALLINCO CBC is DSM's proprietary, linear chain extender additive for polyesters and polyamides. ALLINCO CBC works via reactive extrusion and leads to a cheaper and faster production process for linear, high molecular weight polyesters (PET, PBT) and polyamides (PA6, 6.6 and 4.6) than present post-condensation technologies. No branching or gels are produced. ALLINCO CBC is also very effective as coupling agent for additives or functional groups to polyesters and polyamides or to produce in situ compatibilizers/block copolymers. Current (2010) certified C2C materials The materials have been evaluated by EPEA Hamburg, the consultancy firm of Michael Braungart. This evaluation focuses on the product ingredients human and environmental health attributes and their potential to safely cycle in closed loops. These are; Akulon K224-G6 a 30% glass filled polyamide 6 resin Arnitel EM400 an unfilled thermoplastic copolyester resin Arnitel XG an unfilled halogen free flame retardant thermoplastic copolyester resin Arnite T-XG510 a halogen free flame retardant PBT resin EcoPaXX UF an unfilled 70% bio-based polyamide 4.10 resin All five materials are used in a variety of industrial applications, including furniture, automotive and consumer electronics and were awarded Silver certification Usage related environmental savings Sustainable applications of composites PA 6 in automotive. The ultimate low emission vehicle Polyamide instead of metal oil-pan. Weight reduction. Function integration. Mono material. Weight reduction / car 30% - 0,6 kg KM / car Total KM Fuel reduction * CO2 emission reduction** * Fuel reduction = 0.8 lit / 100 km ** CO2 emission = 2,5 kg / liter fuel Duo-material compatible automotive seat concept Palapreg ECO % weight reduction, mono compatable material DFDA Open structure for air heating & cooling Bio-based resin for automotive vehicle body parts, including exterior panels. Karts use a combination of fuel cell and super capacitors. DSM DEP using tensegrity to eliminate metal hinges Palapreg ECO is composed of 55% renewable resources, making it the composite resin material with the highest bio-based based content available on the market today. Industry testing has proven the high renewable content is without any sacrifice to product performance or production speeds. Hot/cold air in from central console

10 Specialty Coating Resins for Plastics DSM NEO Resins URALAC New bio based paint system for facades. REPAIRABLE Opportunities for material type reduction Improve recycling ECO CO2 based polymers Eco-paxx Eco-paxx partly based on castor oil. New PA 4.10 with improved properties. B4 technology Bio-Based-Building-Blocs From cradle-gate CO2 neutral. PHA (poly-hydroxy-alkanoates) Start-up Novomer uses CO2 to make biodegradable plastics EcoPaXX high-performance polyamide combines benefits of high melting point (approx. 250 C), low moisture absorption and excellent resistance to various chemical substances The role of polymers in the material transformation process is relative new. Innovation potential of Bio-based materials BIO-BASED RENEWABLE FEEDSTOCK Biomimicry We are facing a new Material revolution: Bio-responsive Smart polymers Hybrid "polymers" Convergent technologies: polymers bio technology medical electronics nano etc. Man produce Biomimicry We produce agricultural products by growing Is growing an option to produce artificial products? Slow but eco-effective and local without expensive hardware From exo forming to auto forming Nature grows

11 DSM Leader in White Biotechnology THE X FACTOR Blending Material & Life Sciences Biomimicry Resume Create new business models. Design is the interface between matter & market Gain more control in the overall supply chain. Make the consumer integral part of the chain. Stimulate / participate in material recycling Future feedstock with non-food renewable materials White Biotechnology boost applications of nature s toolset, for example micro-organisms and enzymes, for the production of (fine) chemicals, materials and fuels from renewable resources. X-factor white bio-technology RvdB? 63 DSM-DDW