Contents

Situation/brief/initial spec Mood board Research plan Time plan Existing products page 1 Existing products page 2 C.a.f.e.q.u.e C.a.f.e.q.u.e winner Questionnaire Questionnaire results Questionnaire results and charts Product environment Ergonomics Manufacturing page 2 Manufacturing page 3 Customer satisfaction Final evaluation

Material research
How the bin will be split up Dimensions and sizes Logos and information about the bin Research analysis Design specification Initial design ideas Developing initial ideas and modelling CAD drawings Engineering drawing Photo album

Evaluation of product and conclusion

Material research: plastic

Quality assurance Manufacturing flow diagram Manufacturing page 1

Click on the recycling symbol at any time to return to the contents page

Situation
UK households produced 30.5 million tones of waste in 2003/04, of which 17% was collected for recycling. (source: defra.gov.uk) This figure is still quite low compared to some of our neighboring EU countries, some recycling over 50% of their waste. There is still a great deal of waste which could be recycled that ends up in landfill sites which is harmful to the environment.Bristol city council have been getting a number of complaints about the recycling situation, in that people are fed up of having to put food in a brown box, tins and cans in a black box and cardboard/newspaper just leant up against the side of the other two boxes which inability get blown away, get soggy and get everywhere which makes the street look a mess or gets picked up by kids and get thrown about. So Bristol city council have asked me to come up with a solution for this problem. They have asked for it to be extremely cheap to make as the every home in Bristol will need one. If it is a success in Bristol then the council will think about recommending it for use in the hole of England. Paper Recycling facts Recycled paper produces 73% less air pollution than if it was made from raw materials. Up to 60% of the rubbish that ends up in the dustbin could be recycled. 12.5 million tones of paper and cardboard are used annually in the UK. The unreleased energy contained in the average dustbin each year could power a television for The average person in the UK gets through 38kg of newspapers per year. 5,000 hours. It takes 24 trees to make 1 ton of newspaper. The largest lake in the Britain could be filled with rubbish from the UK in 8 months. On average, 16% of the money you spend on a product pays for the packaging, which ultimately Glass ends up as rubbish. Each UK family uses an average of 500 glass bottles and jars annually. As much as 50% of waste in the average dustbin could be composted. The largest glass furnace produces over 1 million glass bottles and jars per day. Up to 80% of a vehicle can be recycled. Glass is 100% recyclable and can be used again and again. 9 out of 10 people would recycle more if it were made easier.

Glass that is thrown away and ends up in landfills will never decompose Government Targets The Landfill Directive states targets for reducing the amount of waste sent to landfill sites in the UK. The targets are: By 2010, the waste sent to landfills should be 75% of that sent in 1995 By 2013, the waste sent to landfills should be 50% of that sent in 1995 By 2015, the waste sent to landfills should be 35% of that sent in 1995 Plastic 275,000 tones of plastic are used each year in the UK, thats about 15 million bottles per day. Most families throw away about 40kg of plastic per year, which could otherwise be recycled. The use of plastic in Western Europe is growing about 4% each year. Plastic can take up to 500 years to decompose.

Brief
I will design and make a storage devise for a variety of recyclable materials which include newspaper, cardboard, waste food, tins, cans and glass bottles. The storage devise must have different compartments so the materials are all sorted into there different categorise. Much like what the boxes are like today but it will be a collective box holding everything. The storage devise may have to have a lid to protect certain materials being held in the box. It will also have to be as cheap as possible to make as this will be made on a mass scale.

Initial spec
There are a few spec points so far that I have to follow but as I go through the project I will pick up more and therefore refine my idea. very cheap to produce Hold various recyclable materials at once Protect the materials in the box Possibly have a lid

Have Bristol city council logos on, and other companies involved

On this page I have clearly outlined what my situation is, what I am going to do about it and an initial spec which will give me a rough guide to follow, as my research goes on I will add more to the spec to create a design specification.

Mood board

Research Plan
300cm x 400cm Room for all of recyclable materials

Protective coating plastic Vacuum formed acrylic

dimensions

finishes material

Research Mind map

Glass bottles Recycling logos paper Recyclable materials newspaper cardboard food logo

Other companies involved What I need to know

The amount of cans, cardboard, newspaper and food people recycle average between the times they are collected. I need to research the best material that could be used for the jobs I need my product to do. I will need to research all of the different things people recycle as some people recycle different things.

Bristol city council logo Where I will get the information How will I use the information
I will make a questionnaire asking how much materials people recycle and come up with an average. From my knowledge, my teachers knowledge and I will also look into a few specific materials and research them. I will make a questionnaire and put it to people, also I will look at the councils web site to see what type of materials they recycle I will use this information to work out rough dimensions and then feed this back to the people who put the questionnaire to and see what they think for my recycling box. I will apply the information into my design to make sure I use the best material available to me, therefore making my product the best it can be. I will use this information and adapt my design to allow for as many spaces for different recyclable materials as possible to suit every member of the area.

Tins/ cans

On this page I have outlined what my major research areas are, how I am going to research them and also what I am going to do with this information. This will help me to refine my design ideas and come out with the best product possible.

Time plan
Time Plan Situation Brief Time plan Mood board Main research Letters / email Research analysis specification Design ideas

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Development
Modelling Focused research Plan of manufacture Product manufacture Product testing Modification Evaluation On this page I have created a time plan to keep me on track when I am completing my project. This will help me complete my project on time by giving me goals along the course of my project.

Existing products
On this page and the next page I will look at a variety of existing recycling bins some will be ones that are used in the home, some will be ones that are used in public and I will also look at the existing brown and black bins, the ones that I am trying to combine and make better. I will look at the products, make comments on them then later on I will evaluate them I am doing this to discover what makes a good and a bad recycling bin so I can use those certain aspects in my bin that are good. And avoid the aspects that makes a recycling bin bad

This is the brow food recycling bin. On the handles hinge it has a lock to keep it shut which is a good idea as it keeps the box sealed as there is rotting food inside. The design of the bin isn't concentrated on aesthetics but on purpose and only to solve the problem of how to recycle and store waste food.

This is the black bin for recycling tins, cans and glass. As it is only for these materials it is a very simple design. The designs have included handles to make it easier on the person carrying or transporting the bin and have put holes in the bottom and raised it off the ground so it doesnt fill up with water

This is an office recycling bin. It has four compartments for recycling everything in an office like: paper, cardboard, envelopes and printer cartridges. These are quite compact and look like every person in an office would have one of these by the side of there desk to make it easier to recycle.

This is a home recycle bin. It has three compartment to sort different materials from each other. Each coloured box is removable which helps whit transporting materials into the black or brown bin. This product has been design quite well as it is compact, would fit any where in the kitchen and looks very modern.

This bin is much similar to the one before but instead of one big lid each compartment has it own lid. Also the materials are stored in bags inside the bin rather than solid boxes. I think keeping the materials in a solid box is a better idea than plastic bags. As transporting the materials from this bin to the one that is kept outside would be much easier.

This recycle bin is made out of card board and is designed to fix on top of a desk or kitchen counter. It holds paper, cans, card, glass and ink cartridges. Its not very big so it wouldnt be able to store very much. As it is made of card board it means that after a while it would get broken and would have to be replaced. But although it would be very cheap.

Existing products

This bin is for the kitchen and is stackable so the user can have as many as they want for all the things they can recycle. Its is made out of plastic and is durable and will resist quite a bit of wear. It doesnt look like that there is room for a bag so the user would have to un-stack and empty out each bin separately which is a bit of a design flaw.

This is a designer recycling bin. This has been a lot more thought out than some of the other bins, as the aesthetics have been thought about just as much as the function. This has two bins on the side and a pod that come up from the middle that crushes cans. The fact that it is a egg shape on a pedestal gives it a modern look.

This bin like a previous one is a stackable set for the kitchen and allows the user to have as many as they want for all the things they can recycle. These set of boxes are different to the previous ones as they are not as tall which lets the user to recycle a bigger variety of materials but still have room to store materials in.

This bin would be used in public and it would b mass produced. It is colour coded and has pictures to assist the public in what to put in each compartment. This bin is made of plastic as it will have to withstand a fair amount punishment and will be out in the elements 24/7.

This bin is very simple and easy to use as the bags are very assessable, as they are not hid behind any parts of the bin. Once the bag is full up you can just take it out and empty it out into a recycling station. This bin is very practical and it would not take up a lot of room in a kitchen as it is quite small.

These four bins are very modern and stylish. This type of bins would be out in public somewhere not in a house, but there is nothing telling the user what goes in what bin so this could lead to contamination of recyclable materials which could cause a lot of problems further down the line of the recycling system.

These are some very simple and cheap recycle bins and would fit anywhere around a home as they are small. They have written on them what should be put in them in bold letters and to help even more they have the shape of the material cut out of the top so there will be no contamination of materials. These bins have no need for bags as the lid can be taken off and emptied into any bin ready to be collected.

Now I have researched a wide variety of recycling bins and have an idea of what features make up a good recycling bin, I will put some of these into a c.a.f.e.q.u.e to see what is the best recycling bin available to the public.

c.a.f.e.q.u.e
On this page I will evaluate each product and give it a score out of 10 on each of these subjects on the side. 1 being the lowest and 10 being the highest. The product that comes out with the best score, will then be analysed in more depth to see why it came out as the best, what makes a good recycling bin and what makes a bad recycling bin. This will aid me in the later development of my product like the detailed specification so I will know what aspects to put into my product and what aspects to keep out.

COST

10

10

AESTHTICS
FUNTION ERGONOMICS QUALITY USER ENVIROMENT TOTAL

5
9 8 6 8 9 55

5
9 7 6 8 9

6
9 7 8 9 7

8
9 6 6 9 6

4
8 6 6 8 5

10
10 8 9 10 5

6
9 6 6 9 8 52

54

53

54

37

54

This recycling bin came out as the best product with a score of 55. Now I will evaluate it on the next page. I will look at every specific part of the recycling bin like: why it won what is good about the product and what could be improved on it to make it even better than it is. and discuss it and say why and how it contributed to the product winning the c.a.f.e.q.u.e.

c.a.f.e.q.u.e winner
This is the winner from my c.a.f.e.q.u.e on the previous page. I will now evaluate on why it came out as the winner from all the other recycling bins looking at ever aspect of the bin from aesthetics, to the function and to how it was produced and on what scale it was produced. These bins would be made by injection moulding as it is quick easy and cheap. That means that the bins would be made on a mass production scale as person in Bristol would have needed one so they need to produce them as fast as possible. The designer haven't made the aesthetics of the bin there main priority as they decided to concentrate on the function of the box because they needed to make these bins as cheap as possible so they couldnt afford to incorporate much aesthetics into there design. There is a handle incorporated into the design to make it easier for the user to access the box A reinforced handle is used to strengthen and reinforce the locking system and strength of it when carrying the box as it will have a lot of recycled food in it which will be a lot of weight

The bin has a very thick durable hinge because this box will be used on a regular basis as people recycle food everyday.

The hinge of the handle doubles up as a locking system to keep the lid shut as there will be rotting food inside and animals will try and get into the bin.

The box is made out of a very durable plastic as the box will go through some wear and tear and the designers have made these boxes to withstand damage for long period of time. The designers have engineered the boxes dimensions to allows enough room for 2 weeks worth of recycled food to be stored as the collection for recyclable materials is every 2 weeks

The angled shape of the bin makes it a lot easier for the bin men to remove the recycled material. Due to the shape of the box which is angled out wards when the box is tipped upside-down the material inside will just slide out.

Now I have analysed the winning recycling bin from the c.a.f.e.q.u.e I now understand a lot more in what makes a good recycling bin and I will now apply what I have learnt in my design ideas when I come to them further on in my project.

Questionnaire
On this page I am going to create a questionnaire and explain what each question is going to help me find out and how it will aid my development and design of my product.
1. Are you satisfied with the recycling bins available to you at the present time ?

2.

Do you find it a pain and a nuisance having multiple bins to put outside ready for them to be emptied ?

3.

If you recycle paper and card board does it get left on top of the other bins that you have ?

4.

Does your cardboard often not get recycled due to people moving it of it getting blown away in the wind ?

5.

Do you think your current recycling bins have enough room in to store your recyclables until they next get picked up ?

6.

Do you think that an all in one recycling bin would be a useful and worth product to design ?

7.

What recyclable materials do you think that this bin should hold ? waste food bottles tins/cans other newspaper/cardboard

8.

Would such a product like this aid and help to make your recycling responsibilities easier ?

9.

Are there any extra points that you could add to make the design of this product even better ?

10. Would you be interested in trying a product like this for a trail period and giving feed back to show how you got on ?

I have written these questions carefully and thought about each one thoroughly, so I can extract as much information from the general public as possible. My questionnaire is split into two parts. 1-5 and 6-10, 1-5 is about the previous recycling bins and asking the general public if they are satisfied with the facilities that they have at the moment. 6-10 is about a new type of recycling bin and asking the general public is they think it is a good idea and asking them what they think should be included in it.

Questionnaire results
This page is my results of my questionnaire I went out to Bristol city centre and asked 50 people these questions. I made sure I asked a variety of people to make sure my results came from a diverse range of people through out Bristol

1.

Are you satisfied with the recycling bins available to you at the present time ?

Yes 8 no 38 unsure 4
2. Do you find it a pain and a nuisance having multiple bins to put outside ready for them to be emptied ? Yes 40 no 5 unsure 5 3. If you recycle paper and card board does it get left on top of the other bins that you have ? Yes 48 no 2 unsure 0 4. Does your cardboard and newspaper often not get recycled due to people moving it or it getting blown away in the wind ? Yes 35 no 13 unsure 2 5. Do you think your current recycling bins have enough room in to store your recyclables until they next get picked up ? Yes 43 no 6 unsure 1 6. Do you think that an all in one recycling bin would be a useful and worth product to design ? Yes 43 no 4 unsure 3 7. What recyclable materials do you think that this bin should hold ?

waste food 50
bottles 50

tins/cans 50

newspaper/cardboard 48

8.

Would such a product like this aid and help to make your recycling responsibilities easier ? Yes 47 no 2 unsure 1

9.

Are there any extra points that you could add to make the design of this product even better ? The box could have a lid. Maybe have a locking system like the food waste bin. The bin could have a removable section for the food waste part

10. Would you be interested in trying a product like this for a trail period and giving feed back to show how you got on ? Yes 35 no 10 unsure 5

Questionnaire results
1.
Are you satisfied with the recycling bins available to you at the present time ?
yes no unsure

2.

Do you find it a pain and a nuisance having multiple bins to put outside ready for them to be emptied ?

3.

If you recycle paper and card board does it get left on top of the other bins that you have ?

4.

Does your cardboard and newspaper often not get recycled due to people moving it or it getting blown away in the wind ?

yes no unsure

yes no unsure

yes no unsure

5.

Do you think your current recycling bins have enough room in to store your recyclables until they next get picked up ?

6.

Do you think that an all in one recycling bin would be a useful and worth product to design ?

7.
50 49.5

What recyclable materials do you think that this bin should hold ?

8.

Would such a product like this aid and help to make your recycling responsibilities easier ?

yes no unsure

yes no unsure

yes no unsure

49 48.5 48 47.5 47 waste food tins/cans 1 newspapper/cardboard bottles

10.

Would you be interested in trying a product like this for a trail period and giving feed back to show how you got on ?

yes no unsure

These diagrams are the results of my questionnaire. I have put them into a more appropriate style as opposed to writing so that it is easier for people to view them therefore making it easier to understand them. I have missed out question 9 however because it is not possible to put this question into the form of a pie chart of bar graph. I use this information to help me in designing my product later on in my project. The results of my questionnaire clearly show that there is a demand and a need for my recycling bin. As people are not satisfied with the current bins, and the public find it a pain using multiple bins.

From the questionnaire I also learned that the general public think that my project is a good idea, and is worth perusing it.

Product environment

These pictures are an example of the environment that my product will be in. They are outside a house on the street where they will be collected by the bin men, in a laundry room or out side the back door/in there front garden where people will be keep it most of the time. The bin will have to have the right properties to last outside in a range of weathers from heat to snow. It will also have to endure the wear and tear of being used and being chucked around by the bin men.

Ergonomics
Ergonomics is a big part of life. It is involved in everything in one way or another. My bin is involved in ergonomics by lifting and carrying and the strain that it puts on our bodies. This is called manual carrying. Manual handling activities include carrying and moving loads, as well as pushing, pulling, lifting up and putting down. Manual handling doesn't just mean this... ...it also includes all these types of actions.
More than 25% of the accidents reported to the UK Health & Safety Executive (HSE) each year are associated with manual handling, most resulting in lower back injuries. With about 70% recurrence rate for back injuries, it's much better to avoid getting an injury, than to try to fix the situation afterwards. Although some manual handling injuries are due to a single incident, many are cumulative and result from carrying out the same activities repeatedly, with poor posture. Nursery school teachers are an example of an occupational group who are exposed to cumulative risks. They can involve lifting from a low level as well as bending forward to talk to and feed young children. It is not just the back that may be injured. Other muscle groups and joints such as shoulders, arms and legs, are involved in manual handling and may be damaged by bad lifting techniques. Feet can also be damaged by loads being dropped on them. You can decrease the risk of injuries by thinking about how you handle things, and using efficient and comfortable working postures during the handling activity.

The structure of the back allows it to support our head, to provide anchor points for the rest of our skeleton, and provide flexibility when we move. The vertebral column is formed of 33 bones, called vertebrae. It has four curves, two of which, thoracic and pelvic, are concave and are formed before we are born. The other two, cervical and lumbar, are convex and are formed when we begin to sit up and walk. The vertebrae are bound together by powerful ligaments, and stabilized by small muscles along the entire length of each side of the vertebral column. The joints between the bones of the lumbar, thoracic and cervical regions are slightly moveable and contain fibrocartilaginous structures called discs. The discs act as buffers (shock absorbers) between the vertebrae to withstand forces of compression. Although the amount of movement between any two vertebrae is limited, the sum of the movements which take place at all the joints make the spine, as a whole, a very mobile structure. The spine can bend forwards (flexion), backwards (extension) and sideways (lateral flexion), and can twist (rotation).

From this page I have learned that manual carrying involves a vide variety of tasks and that it can be very easy to injure your self when lifting heavy objects, and not just in your back but all over your body, and people should think more carefully when carrying heavy objects and making sure it is safe to do so, so they wont injure them-self's

Materials research
Metal
As with wood There are lots of types of metal with each having there own qualities. Such as they are good conductor of electricity, heat and strong. Also there are a wide range of alloys available for special purposes just as the air craft industry they are used because alloys are a mixture of metals there fore getting the optimum strength and good qualities. Metal is also harder to work than wood and often specialised tools and machinery are required but they can be heated up to be made more malleable. As with wood there are a lot of ways metal can be joined such as welding, soldering, riveting and bolting. Every type of metal is used for something different and therefore is used for some thing different.

Wood
There are lots of types of wood with each having there own qualities. Such as colour, strength, weight and ease of working and price. Other advantages of wood are that it will readily take a wide range of finishes such as paints, vanishes, stains and waxes. It also has a large amount of ways it can be joined, screwed, nailed, jointed and glued. There are two types of wood, man made and natural. Man made woods consist of plywood, block board and mdf. Natural woods consist of pine, ash, oak and mahogany. Each have there own unique qualities and are very different. The main defining qualities are the colours and the grains. But coloured vanishes are available to make a cheap wood look like a very expensive wood.

Plastic
Plastic is the general term for a wide range of synthetic or semi synthetic polymerisation products. plastic comes in a wide variety of colours styles like solid colour translucent colour and clear. They can also be bent and formed into any shape. the two mane types of plastic are thermosetting and thermoplastics. Thermosetting can only be heated up and shaped once but thermoplastics can be heated shaped and reheated and reshaped. It is also used for a hugely wide amount of products all having there own very different characteristics, plastic is the most varied material, much more than metals and woods.

From researching these materials I now know that I am going to make my product out of plastic. I will make it by either injection moulding or vacuum forming. What specific plastic I do not know what I am going to make it out of but I will research this at a later date in my project.

Research on how the bin is going to be split up

In my box I will incorporate the black bin, brown food bin and a space for paper and newspaper. The recycling bins at the moment are separate this is not because the council necessarily wants them like that but because that the recycling bins were brought out at a different time to each other.

The materials that can be put in the black bin are: The materials that can be put in the brown bin are:
Food and drinks cans Newspapers and magazines Yellow pages and telephone directories Glass bottles and jars Clothes, blankets and material Pair of shoes Aluminum foil and containers Household batteries, including rechargeable Spectacles Aerosol cans fruit and vegetables meat and fish cooked and uncooked food leftover food bread, pasta, cereal and rice tea bags and coffee grounds dairy products and eggshells bones small cardboard items (e.g. toilet paper rolls or egg boxes) small amounts of shredded paper

Other materials: News papers Cardboard boxes

I have to allow enough room for these materials in my all in one recycling bin. I will create a few different layout designs and then score them on what I think is the best layout is to fit a wide range of materials in.

1.

2. Food waste Food waste Tins/Cans

3. Food waste Tins/Cans

4. Newspapers Food waste Tins/Cans

Newspapers

Tins/Cans
Newspapers 7/10 8910

Newspapers
8/10

From doing this I have learned that newspapers and cardboard can be flattened so that section will not need as much room as the others. I think tins/cans will take up the most room in the box as there is a lot of wasted space in the empty tins and cans as people do not crush them to fit more of them in the box. I will work along the lines of model 1, 3 and 4 as this allows as much room as possible for the tins/cans and food waste but it still gives quite a lot of room for newspapers.

8/10

Research on dimensions and sizes

On this page I am going to research the dimensions of the 2 recycling bins. The black bin for tins, cans and glass bottles and the brown recycling bin for waste food. I will research the dimensions for both bins and then come up with rough measurements for my bin, this will allow me to be more flexible with my design ideas if I do not put a specific dimensions on my box as some of my design ideas will vary, and this will allow me the most flexibility when it comes to the trade off between size and design. 270mm 270mm The measurements that I have taken is from the inside of the bin as this will give me the correct measurements for the volume of the bin. 490mm 340mm Now that I have researched the measurements of the bins I will design three different types of measurement combinations to see what is the 430mm best for the combination of the two bins and allows my bin to give as much volume as possible, and gives just a much space inside as the 240mm two separate bins put together. 490mm 270mm

As I am going to make the measurements for the top bigger I wont need to change the height of the bin that much otherwise the bin will be massively bigger. So I have decided to keep the height between 240mm and 30mm

340mm

270mm

This is a layout and the dimensions of the current two bins. I will now look at the measurements and develop rough dimensions for my product. And not forgetting I have to allow space for news papers and cardboard. 600mm 550mm 490mm

450mm

400mm

490mm

Now that I have come up with a range of measurements that are reasonable and practical I will put this into my design specification. Which will give me a set boundaries (that I will not go bigger or smaller than) to work with when I come to designing my product

Research on logos and information for the bin

On this page I will look at a variety of logos that I could use and then decide what ones I will use. Below are a variety of logos that are used in the recycling advertisement campaign and that are already being used on the current bins.

the logos that I have decided to use and put onto my bin are the city council logo, the sita logo (they are the company who collects are sorts the rubbish) as I think these two logos are the most important ones because they are already on the current recycling bins. I have also decided to add the new recycle logo. As this bin is meant to be a promotional bin in Bristol so I thought it was essential for me to incorporate this logo into my design. I will most likely engrave these logos on to the box using a laser cutter when I cut the product out as I think I am going to use acrylic because it fits my design specification . Or if I do not used the laser cutter to cut my project out I think that I will use a transfer sticker or paint then on with a stencil as this is how they are out on the bins at the moment.
From carrying out this research of logos I have learnt that the best logos for me to use on my bin are the Bristol city council logo, the sita logo and the recycle for Bristol logo.

Research analysis
On my specification page I have clearly outlined what my situation is, what I am going to do about it and an initial spec which will give me a rough guide to follow, as my research goes on I will add more to the spec to create a design specification. My research plan helped me to outline what my major research areas are, how I am going to research them and also what I am going to do with this information. This will help me to refine my design ideas and come out with the best product possible. my time plan will help me to keep me on track when I am completing my project. This will help me complete my project on time by giving me goals along the course of my project. Now I have researched a wide variety of recycling bins and have an idea of what features make up a good recycling bin, I will put some of these into a c.a.f.e.q.u.e to see what is the best recycling bin available to the public. My c.a.f.e.q.u.e helped me to understand a lot more in what makes a good recycling bin and I will now apply what I have learnt in my design ideas when I come to them further on in my project. From my questionnaire I learned that the general public think that my project is a good idea, what else to put into my product and is worth perusing it. My environmental research helped me to learn what properties that my bin will need to be successful in my chosen environment. My ergonomic research have learned that manual carrying involves a vide variety of tasks and that it can be very easy to injure your self when lifting heavy objects, and not just in your back but all over your body, and people should think more carefully when carrying heavy objects and making sure it is safe to do so, so they wont injure them-self's From researching the three main materials I now know that I am going to make my product out of plastic. I will make it by either injection moulding or vacuum forming. What specific plastic I do not know what I am going to make it out of but I will research this at a later date in my project.

From researching recyclables and what can be recycled I have learned that newspapers and cardboard can be flattened so that section will not need as much room as the others. I think tins/cans will take up the most room in the box as there is a lot of wasted space in the empty tins and cans as people do not crush them to fit more of them in the box. I will work along the lines of model 1, 3 and 4 as this allows as much room as possible for the tins/cans and food waste but it still gives quite a lot of room for newspapers.
Now that I have come up with a range of measurements that are reasonable and practical I will put this into my design specification. Which will give me a set boundaries (that I will not go bigger or smaller than) to work with when I come to designing my product From researching logos it has helped me to decide what are the correct are best logos that i should put onto my bin

Design specification
Material
From researching I have learnt that plastic is the best material to use as my product will eventually have to be mass produced so there for its will have to be vacuum formed or injection moulded and the best material for this is acrylic plastic. It will ensure that my bin is strong and durable to resist the wear and tear of daily life and it doesnt necessarily need any type of finish although I will determine that at a later stage.

Layout
I am going to work around the layout of the two diagrams below. This is because it will allow enough room possible for the tins/cans and food waste but still allowing leaving room for cardboard/newspaper down the side.

Sizes and dimensions

From researching the dimensions of the current recycling bins I developed three different bin sizes that were both reasonable and practical from this its gave me an overall boundary for my design spec which will aid me in my designing. As I am changing the area of the top I decided to keep the height pretty much similar to the black bin but I have allowed it to move up to 300mm if there is any extra space needed in the bin. I may make a half scale model depending of the amount of material available. 600 - 490mm 240 - 300mm I will also create a leaflet to go with the recycling bin. This will explain everything to the user, get them more encouraged in recycling and have facts and figures about the recycling problem as it is today. I will include certain logos and characters that are involved with the current recycling ad campaigns at the moment. 490 400mm

Logos and information

I will incorporate these three logos below. As these are already on the current recycling bins at the moment. The logos are of the Bristol city council. Sita, the company who collects the recycling and the recycle for Bristol logo. I will also include certain information that is already on the bins that tells the users about the bins.

Scale of production
The scale of production for my project will be one off but it would be very easy to convert my design into a scale of mass production as it could just be injection moulded as two pieces

Other functions
The bin will be green to fit the recycling colour trend. The bin must be made for as little as possible

The bin must be manufactured as quickly as possible. The lid will maybe have a locking system like current bin if possible. The food waste part may be removable.

Initial Design ideas

This page consist of my initial design ideas. I have used my design specification to create a variety of designs but which also adhere to my design spec. On these few pages I will annotate my designs. And then give a brief description of what I think about the design and then evaluate it with a mark out of 10. all of these designs will be vacuum formed

This design follows the same lines as the black recycling bin. But it is split into two sections at the top. And has a compartment in the bottom for newspapers which I think is the best layout for space. 9/10

This design is quite unusual but I think the bin is laid out very well. With the middle split into two and an out side ring for newspaper although carrying it may be difficult due to its shape. 8/10

This design is a stackable bin. But each section can also be laid out next to each other. This would make it more user friendly but I would have to develop a way to keep the attached when stacked. 7/10

This design is made to fit against a wall and a sliding lid covers up the food waste and keeps the smell in the box. Although a semi circle may not be the best shape for cans and tins to fit in.. 8/10

This design is an unusual design as the squares on top are hooks for plastic bags to keep the recyclable materials in. it is possible to keep 3 bags on this design. Although there is not a bin for the food

This design follows the other black bin design I have, but it has a detachable food waste part. This will make it a lot more user friendly but It may be not as strong with a detachable part. 7/10

This is a very simple but effective design as the middle bit is for cardboard. And either sides are for food waste and cans. But there is no way of carrying it at the moment. 8/10

Developing initial ideas and modelling

I have decided to develop this design idea as I think it is a good innovative idea that is a lot better than just a black square box, and yet it also has potential to be developed into a very good product.

This is my development of my initial idea. I have changed the shape of it to make it look more aesthetically pleasing. And to give it a bit more of a natural/organic look and shape as it is a recycling bin. I have also put the hooks for the plastic bags in the wall of the frame this lets the lines of the designs flow better and give it a sharper look. I have not put 3 sets of hooks on the frame but only 2 as I will put a removable bin on the end for food waste. This will make it easier for the user to when it come to food waste disposal as the box will have a lid and will not let any smell out.

Now I have modelled my design idea and have tested it to see if it works as a product not just as a drawing. I am now going to design my idea on a CAD programme. The CAD programme I will be using Prodesktop as I can use this programme to a high level and I am very familiar with it.

CAD drawings

Engineering drawing

Photo album

Material research : plastics

introduction Plastic is the general term for a wide range of synthetic or semi synthetic polymerisation products. plastic comes in a wide variety of colours styles like solid colour translucent colour and clear. They can also be bent and formed into any shape. the two mane types of plastic are thermosetting and thermoplastics. Thermosetting can only be heated up and shaped once but thermoplastics can be heated shaped and reheated and reshaped. It is also used for a hugely wide amount of products all having there own very different characteristics, plastic is the most varied material, much more than metals and woods. Acrylic Acrylic the most common acrylic plastic is Polymethyl Methacrylate it is a thermoplastic which is very cheap and Light but strong plastic. Which is Widely available in sheet form. it is used for a wide variety of applications like school projects like vacuum forming because it softens at about 95C. it is available in a wide variety of colours and thickness. Finishes Due to the make up and the characteristics of plastic there are not many finishes for plastic. The only ones there are is polish, it makes the plastic look shiny and will be best applied by a buffer but provides no protection at all. Wire wool can be applied to make the edges a lot smoother and rounded but again provides no protection at all. Another method of finishing plastic is a antistatic finish it is a cream of a spray that prevents dust attraction. But this is usually a specialist finish and should only be applied where dust would cause a problem. Manufacturing Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity (manufacturing processes reference guide, p240).

Vacuum forming is a simplified version of thermoforming, whereby a sheet of plastic is heated to a forming temperature, stretched onto or into a single-surface mold, and held against the mold by applying vacuum between the mold surface and the sheet. The vacuum forming process can be used to make most product packaging, speaker casings and even car dashboards. Normally, draft angles must be present in the design on the mold (a recommended minimum of 3), otherwise release of the formed plastic and the mold is very difficult. Environmental issues Speaking generally plastics are not very environmentally friendly as the molecular bonds that make plastic so durable make it equally resistant to natural processes of degradation. This means that they will just stay around for hundreds of years. Possibly giving out harmful chemicals, damaging the environment or animals. Unfortunately, recycling plastics has proven difficult. The biggest problem with plastic recycling is that it is difficult to automate the sorting of plastic waste, and so it is labor intensive. Research has been done on biodegradable plastics that break down with exposure to sunlight (e.g. ultra-violet radiation), water or dampness or bacteria. Some researchers have actually genetically engineered bacteria that synthesize a completely biodegradable plastic, but this material, such as Biopol, is expensive at present.

Quality assurance
Quality assurance checks the system that makes the products before, during, and after manufacture. It ensures that a high level of consistency is achieved when it comes to the quality and standards.

I will make a number of quality assurance checks along the way of the manufacturing of my product.
First of all I will cut my product out on a laser cutter so I will know that all of my components will be virtually perfect to the measurements that I drew it up in, in Prodesktop, and a lot more accurate than me cutting out by hand and also the laser cutter will give it a much better finish especially when I engrave my logos on it will be permanent as opposed to spray painting my logos on. There is one weak link in my project which could effect my quality of my project. Which is the mould that I will make to create the curved piece of my removable bin. It will not be perfectly fitted to the same curve of the out side bin, and as I am making the mould out of plywood the finish of the piece of plastic will be slightly ridged and bumpy.

British and standards

British Standards are produced by BSI British Standards, a division of BSI Group that is incorporated under a Royal Charter and is formally designated as the National Standards Body (NSB) for the UK. Products and services which BSI certifies as having met the requirements of specific standards within designated schemes are awarded the Kite mark.

European standards
The CE marking (also known as CE mark) is a mandatory conformity mark on many products placed on the single market in the European Economic Area (EEA). The CE marking certifies that a product has met EU consumer safety, health or environmental requirements.

British and standards Kite mark

European standards ce mark

Manufacturing flow diagram

start
Turn on and set the oven to 165 degrees and wait yes Import dxf file in to galad Is the information correct ? Is the oven at 165 degrees ?

Once all the plastic is glued together take the plastic out of the wood mould Glue all of the pieces together the were cut out on the laser cutter with tensile cement

Glue the sides of the bin onto the bent piece of plastic

no
yes
Put the piece of acrylic in the oven and wait for 5 minuets

Is there any excess plastic over hang yes

Import design into galad Measure a piece of 3mm acrylic for the mould when wood is glued together sand mould down until smooth

no

Take the acrylic out of the laser cutter Trim down any excess over hang of plastic

no

Put wood into the C.N.C, enter dimensions and focus the cutter Check product size and that all lines are hair line

Take the acrylic out using protective gloves, put in the mould, and put mould in vice and leave to cool Import dxf file in to galad

Check the job on the laser cutter and select start yes Is the information correct ?

Glue the back of the bin on with tensile cement

Take the wood out and glue mould together with p.v.a and leave over night
Check the job on the C.N.C and select start yes Is the information correct ?

Export it as a galad file and import into coral draw

Glue the lid to together and fit.

no
Print design and enter necessary information to print yes Are material, product dimensions correct and are all lines hair line ? Put the smaller bin inside the bigger one .

no
Are material, product dimensions correct and are all lines hair line ?

Put the acrylic into the laser cutter, enter dimensions and focus the laser Check product size and that all lines are hair line

finished

yes
Print design and enter necessary information to print

no

no

Manufacturing
Making the mould

To make the curved front panel I cut out the side panel to my bin 7 times, sanded and cut the seventh piece down to 11mm to make all of the pieces the correct size when put together. I then gulled them all together to make a mould. I then put a piece of acrylic in the oven to make it very malleable so I would be able to bend it around my mould. Unfortunately it did not work properly so I decided to make the outer part of my mould. This would ensure that my piece of plastic would bend and fit to the shape properly therefore giving me the shape I want.

I cut the outer part to the mould out and then gulled it together with p.v.a glue and leaved to dry over night. I then sanded it down and tried to bend the plastic again and discovered that I didnt need the back part to the mould and just put the inside part and front part in a vice.

I had the piece of plastic and the curve I wanted but it was quite lumpy due to the fact that plywood was used for the mould which gave it a bad finish to it but I decided now to cut out the rest of the bin and see if it all fitted together.

Manufacturing
Making the rest of the recycling bin

I cut the bin out of acrylic on the laser cutter and then glued it together with tensile cement and leaved to dry. The bin came out extremely well and just how I hoped it to.

I glued the walls and the back of the separate bin together and fitted that in, and it went in well and fitted snugly. But unfortunately the moulded piece of plastic was to big because I made the mould straight from the side of the bin and did not take 3mm off of the whole shape.

So I added a moirs and tennon joint on the sides of the bottom piece and the bottom of the side piece the side pieces joint is protruding down 3mm extra to allow the curved section to fit the other part of the bin.

Manufacturing

I next made a mock up of my separate bin. Then I cut another acrylic model out glued it together with tensile cement but because I had to glued the sides to my smaller bin on the inside of the bent piece plastic. The bigger bin was again 3mm to short so I had to go back to Prodesktop and make the mortise and tennon joint 3mm lower. This was my final model as when I cut it out and then glued it together it all fitted to a high standard. The top of the removable bin was not poking over the top of the main bin, when you put the smaller bin inside the other one and looked at the profile of it you couldnt see the removable bin. so I then decided to cut it out for the final time

Manufacturing final cut out

Like I said in my design specification I engraved these logos onto the side of my recycling bin, to give it a more high quality and professional look. As it is for the Bristol council. Like all of the other models and prototypes I just cut all of the components out and the glued them together with tensile cement. And I decided to glue some feet on to the bottom of my product to finish it off and make it look just that little bit better. Although when I used my mould to make the curved piece the plastic shrunk by 3mm width ways so I had to do it again and I added on 3mm to the overall width to allow for this problem.

As you can see from the picture on the bottom right the new piece of plastic that I bent was a lot more accurate in how far away it was from the sides. This is as close as I will get it because it is joined at the bottom the difference between each side at the bottom is 119mm and the top is 121mm this is due to the fact that the sides move slightly outwards due to how it was manufactured. If it was manufactured in industry it would be made out of one piece of plastic and the difference between each side would be 119mm all the way up.

Customer satisfaction
As I made my recycling bin for the general public. I went back to the Bristol city centre with my half scale model introduced what I have been doing in my project and asked another questionnaire based on my specification, and the design features and saw what they thought of the product that I have produced.

I went down to Bristol city centre and randomly selected people from the general public to ask about my product. I showed them the product I have produced, and then asked them a series of questions which were based on my specification and design aspects. I also asked if they had any specific comments about my product. The comments that I received were as followed. The public said that they were surprised about how I turned the old recycling boxes in to such a interesting and innovative design. Other comments that I received were about how good it looked. And how it was a change to bland boxes, and that the incorporated food waste bin was a very good idea and it was the right choose to make it follow the curve of the design. One of my final comments that I received was that the holes in the side for the bags to go was a good idea. And it gives a use for plastic bags that are just sitting in the cupboard.

Customer satisfaction questionnaire

Do you think the layout of the recycling bin is the best that could have been achieved ?

yes 26

no 4

Do you like the removable food waste bin ? yes 29 no 1 Do you like Idea of putting plastic bags in the recycling unit and the putting the recyclables in the bags ? yes 27 no 3 Do you think the size of the recycling bin is big enough ? ( bearing in mind my product is a half scale model )

yes 28

no 2

Do you think that this could be a particle and everyday item that you could use ? yes 29 no 1 Do you think it would be easier to use my product compared to the current recycling bins yes 23 no 7 Do you think that what I have been doing over the past few months has been successful ? yes 22 no 8

As you can see that my project has been successful, and I have created a good product. But I will talk about this questionnaire more on my next page in my final evaluation.

Final evaluation
On this page I will evaluate my whole project I will look at how well I developed my design, how well I manufactured my product and how well my product came out of the design process

Research and Development

First of all I researched existing recycling bins but I failed to find any product that was what I was designing my product for. I went out to Bristol city centre and asked the general public about the product I was going to be making and what they think I should include into it. I also carried out a c.a.f.e.q.u.e of all of the products I researched chose a winner and then analysed it in depth and looked at why it came out as the best and what things I could Improve on when making my product . I then took that information and added it into my design spec. I then carried out some specific research on sizes, dimensions, layout and logos that I will put on my product. All of this research helped me to refine me design spec and helped me create my design ideas. Once I had completed my research I had a idea of what my designs would look like but I had some trouble using my specification to think of designs that would be a very good innovative design rather than a boring box, but I did come up with some designs and then I looked at them and decided were not going to work or would be very difficult to make and hard to use. I decided to develop my idea that held bags in which the recyclable materials would be held, because i thought that it would be the easiest to use and it is the idea that was most suited to my specification and had the most scope for development. I developed my idea to have curves on the side to look very organic and fit with the recycling theme. When I thought that I had developed my idea and solved all of the problems I made a card board model which worked so then I decided to make a prototype. I did this to see if my product would work or if I needed to make any more adjustments, this helped me because it gave me a much better idea on how my product would work. I had a lot of problems with the height of certain things and how everything fitted together. I think this came from where I scaled down my designs to a half scale and the transition of drawing my components up in Prodesktop and manufacturing them. Especially the curved piece as I drew that in Prodesktop and assembled it and it worked. But when I made it in my mould it was the wrong size. so I developed the idea some more but then again I still had some issues when I made the separate bin which was that the separate bin was still too tall for the main bin. So I chose to develop it again by adding 3mm on the bottom of the main bin and made another prototype which then worked. The I decided to move on to manufacturing. I think that I developed my design very well although it is quite different from my initial design, but then that shows that I developed my idea extremely well even though i came across unforeseen problems that could of only been know while manufacturing my product to show people what my product is about and what it does.

Manufacturing
After I had made quite a few prototypes I found manufacturing everything very easy apart from the curved piece of plastic which I had only made once. To manufacture my main bin was very simple all that was required was to cut the pieces out on a laser cutter and glue them together with tensile cement using a square piece of wood to get the join as a right angle. When I attempted to make the curve piece of plastic it came out quite well but then constructing the bin around that was quite hard, this was because of the shape of the curved piece of plastic it was hard to fit the sides to it using tensile cement as the profile of the side wasnt a perfect match to the inside of the curved piece this was due to imperfections in the mould but I think I did quite a good job of handling it and doing the best that was possible. I am very pleased with my final product as the process of initial ideas to developing and then manufacturing has worked very well for me. I have manufactured a product that solves that problem that was put forward and solves it well. When I was making my product and the I think it came out as a total success I think that my recycling bin is a very good product which solves a problem extremely well and went through and came out the design process with great success

C.a.f.e.q.u.e
To see if my product is successful, and does a better job than the existing products that I researched I will perform a c.a.f.e.q.u.e. if my product gets a better score than the best recycling bin that I found in my previous c.a.f.e.q.u.e then along with my customer satisfaction and evaluation this will help me to draw the conclusion that my product is successful. COST AESTHTICS FUNTION ERGONOMICS QUALITY USER ENVIROMENT TOTAL 9 9 9 7 8 9 8 61
55 61

My product scored 6 more points than the highest scoring product that I researched so this proves along with my customer satisfaction and my evaluation that my product is more successful than any others that I found.

Conclusion
From carrying out my customer satisfaction interview and questionnaire, evaluation and a final c.a.f.e.q.u.e of my final product I have come to the conclusion that my product has been successful in how it has gone through the design process and come out as a working product and how that the user who it was made for: the general public of Bristol think that it is a good idea and that they thought there was a problem to be solved with the recycling bin, which I also solved well and properly.