products based on biomaterials and as third you'll seesome demands on the design with biomaterials forsucessful products.

Welcome to mehrwerk designlabor's presentation"Design with Biomaterials".Our presentation is dividedin three parts, a short theoretical prelude, then, assecond, we would like to introduce self-developed

"Design with Biomaterials" - Green DesignErnst-König Straße-2

06108 Halle/ SaaleTel.:+49(0)345-775158040Fax:+49(0)345-775158001

http://www.mehrwerkdesignlabor.de

range to more climate-friendly products. B.t.w. fordevelopers often a granular already is a finished product.As designers we need to understand new materialswhich includes the material properties, the entireprocess chain and the processing of materials. Structuralimprovements by lightweight constructions, like optimal

Here we see the background of our work. Weunderstand mehrwerk hereby as mediator betweenthe two poles research and sales. Designing ortranslating the positive results of research into livelyproducts. Most manufacturers now have recognizedthe signs of time and want to expand their product

use of the material properties, are important here aswell as the image a product carries itself. ultimatelythe producer, the designer and the developer go likelywith a successful, because convincing product.

mehrwerk designlabor

mehrwerk designlabor, mehrwerk.net, design-coop

HKD Burg GiebichensteinProf. F. MeinelEnrico Wilde

Studentenprojekte

Fraunhofer IWM Halle FH Zwickau

Gorilla Cases Berlin

Deutsche BahnQuipso PowerslideBlatand

Jacob Winter GmbH

SWAPDracosa GmbH

Hemp 2 Use

Vertrieb

Hersteller

Institute

Gestalter

Kunde

The reinforcing components can now be replaced bytechnical materials such as glass or carbon fiber, theadhesive component is then shifted direction epoxy orpolyester. If we want to make a positive environmentalbalance and less waste problem, we shift thecomponents more in the direction of the green materials,

Here we see a composite material made of concreteand steel, as used in construction. Good connectionof the stiffness of the steel associated with the hardnessof the concrete, so you get a mix of properties. Whichon the surface of this foto doesn't look good becausethe fiber-matrix adhesion at this point is insufficient.

like natural fibers and bio-resins.

Verbundwerkstoffe

Armierungskomponente• Stahl• Technische und natürliche Fasern• Gewebe• Pflanzenbestandteile• ...

Matrixmaterial/ Kleber• Beton• Thermoplaste• Duroplaste• Stärke• Kautschuk• ...

Stahlarmierung im Beton

20%, one could wonder where the course is to be. Thereason is that big an most parts lay behind the cladding,hidden very good. So we are working bringing thebiomaterials to the surface.

Besides the know-how about the components and theproperties of the materials also the, let's say, identityof the material is important. Important decision criterion,in addition to the price, is the quality and the appearanceof the product. If I now say that in a modern car in theinterior the use of renewable materials is bigger than

Verbundwerkstoffe

Attraktivität & AkzeptanzUnsichtbare Unterkonstruktion

PKW-Interieur

Türinnenverkleidung aus einem naturfaserverstärktenVerbundwerkstoff DLR

next, the press-forming of parts and panels. As fourthwe see the extrusion, where a hot mass is pressedthrough a pattern and the injection molding, here tosee at the example of connectors for furniture madefrom hemp fiber and lignin. As the penultimate thepressing of insulation panels and finally the vacuum

Here we see industry's main manufacturing methodsfor the production of products in which biomaterialscome into play. Most of them can be simulated in theown worhshop for the design process and the prototypebuilding. It is mostly hard work, but worth the effort.On the left side we see the fiber winding pultrusion.

method, used for complex composite parts with highattributes as leightweight and performance.

Überblick Fertigungsverfahren

bio-image from the 80s, the lounge chair emphasizesthe efficiency of the materials used.

Welcome to the second part, the presentation of thedeveloped products. We start with the lounge chair,the last example of the processing methods. Demandswere, besides seating comfort, economical use ofmaterial, use of natural materials, lightweight andstrength. According to a modern bio-image, far of the

• Sparsamer Materialumgang• Natürliche Werkstoffe CO2-neutral

• Leichtgewichtigkeit• Strukturfestigkeit und Hochwertigkeit durch Naturfaser

Lounge-Chair: Anspruch

vacuum pump sucks it in.Here we see a sketch of the processing of the loungechair, the vakuum-laminating method. Hereby fabric,soaked with a matrix material, is placed in a mold,sealed with a thin foil and evacuated, which creates apressure under which the material hardens then. Theexcess resin is collected in a reservoir before the

Lounge-Chair: Fertigungstechnologie Vakuum-, RTM-Verfahren

structure.The materials of the lounge chair are the following:fabric made from hemp fiber, the bark from the fig tree,called in hereinafter by its trade name 'bark cloth', ornatural silk on a different model, paper honeycomb inthe inner and an epoxy matrix from linseed oil. On theother side as well, making it a very solid sandwich

Lounge-Chair: Materialien/ FEM-Berechnung/ Schlagzähigkeit

HanffasergewebeFeigenbaumrindePapier/ PappeNaturseideNatives Leinölepoxidharz

= Leichtgewichtigkeit= natürliche Werkstoffe

Lagenaufbau

lounge chair.The geometry of the chair is due to a rectangle whenflattened. Fabric can be used as it comes from the roll,no sclicing and no cutting is necessary. The chair isbased on a form of origami principle. So the materiallosses are minimized. This geometry, combined withthe sandwich construction, gives great stability to the

Abwicklung und Modell von "AufJedenFalz"

Verlustfreie Fertigung= sparsamer Materialumgang

Lounge-Chair: Abwicklung

Here you can see us by attaching the vacuum foil onthe soaked fabric placed on the mold. Left pictureshows the hardening under the already evacuated thinfoil which is pressing the layers against the mold.

Lounge-Chair: Werkstatteinblick

Fertigung eines Prototypen im Vakuumverfahren

Here you see details from the first prototype, the tactilesurface, the visibility of the sandwich structure on theouter edge and the leightweight, a total of 5kg for morethan a 120kg human.

haptisch sandwich leicht

Lounge Chair: Details

= textile Gestaltung der Armierung

Here in picture you see the result of the secondprototype with textile designed and woven layer ofnatural silk. The silk printing was clearly applied beforethe production process, as the layer of natural silk wasstill flat.

Lounge-Chair: Modelle

Here are the fine details of the second prototype. Onthe front we have a layer of natural silk, on the backbark cloth. Both gives a good strenght to the chair andcan be designed, in opposite to glass and carbon fibre,with, for example, silk printing techniques.

bosozoku-style kantig silkappeal

Lounge-Chair: Bedruckbar, Konfektionierbar...

Textile Anmutung, planare Gestaltung, dreidimensionale Anwendung

of about 70% wood and 30% plastic. Demands on theExtruso shelf were the good industrial manufacturability,the user-friendliness, use of natural materials, varioussurface variations and the non-visibility of theconnectors.

Second example in the product category is the extrusionshelf system, called Extruso. It is a collaboration withthe Fraunhofer Institute for material mechanics.Fraunhofer here is responsible for the development ofcompounds and the hollow structure of the panels. Itis a recipe from wood plastic composites, thus consist

• Herstellbarkeit keine Substitution von weniger komplexen Werkstoffen

• Nutzerfreundlichkeit Transportierbarkeit, leicht Aufzubauen, Erweiterbarkeit

• Natürliche Werkstoffe CO2-neutral

• Unsichtbarkeit der Verbindungselemente• Oberflächenvariationen

Extrusoregalsystem: Anspruch

At the extrusion process a hot and pasty compound ispressed through a pattern and cooled slowly on acertain bending range. The cavities are also createdby the tool spikes in the inner.

Extrusoregalsystem: Fertigungsverfahren

Here as an example in the picture top left the utopiaof completely green extrusion by the Danish designerJürgen Bey, which uses easily garden waste for newand good looking furniture. In reality the essentialmachinery seems a lot more martial. But very nice tolook at the pattern tool and the bending range.

Extrusoregalsystem: Extruder und Richtstrecke

Extruder WPC-Hohlkammerprofilplatten, Fraunhofer IWM

Jurgen Bey, "Gardening Bench"

Here we see a cross section of the extruded panel. Asyou can see it is quite hollow. Used in our shelf system,it ensures not only for structural lightweight, but alsofor the connection of the panels themselves.

Design mit Löchern

Zusatzfunktion

StrukturleichtbauHohlkammerprofilOberfläche

VerbindungElektrifizierung

Klimatisierung

...Beleuchtung

Querschnitt einer extrudierten Platte

Extrusoregalsystem: Querschnitt einer Hohlkammerplatte

system. From the outside the connectors are, hardlyvisible, spread with a chip and get anchored in thehollow sections. From the outside it looks like this.Here in the photo you see a very light mixture of lightwood and the spreading chips.

For the connection of these panels we use a specialdesigned universal connector that can assemble withhis fellows to all situations that occur in the constructionkit. As material also hempfibre reinforced plastic isused. Currently the mold for the connectors is gettingproduced, there will be a small series of our shelf

Verbindungselemente semantisch und funktional

Extrusoregalsystem: Verbindungselemente

A relatively large prototype of the shelf system you seehere transported in the trunk of a VW Lupo. Of coursethe connection is reversible.

Extrusoregalsystem: Transportierbarkeit

Prototyp des Extrusoregals findet im kleinsten Transportmittel Platz

And so imagined and visualized the Extruso could lookin an office. By bracing the connector into the hollowsections, the back wall bracing gets obsolete. DifferentWPC recipes provide color gradations. The Extrusoshelf system can be scaled, due to the modular principle,in any broad or height, also subsequently.

Visualisierung Regalsystem im Büro

Extrusoregalsystem: Funktionsintegration

Interesting here is the surface structure, which developsevery time a little different. If we mean to cultivate suchaccidents in industrial products, each product will carrya personal note and thereby getting unique.

A final interesting aspect of designing biomaterials isthe handling concerning the apperance and the naturalvariances of the material. Biomaterials are by naturesuspended, even more stronger than their petrochemical pendants, to natural fluctuations of course.Here we see a box made of injection-molded WPC.

Extrusoregalsystem: Oberflächenvarianzen...

Beispiel WPC-Spritzguss bei hoher Verfüllung mit Holz

time and joined seamlessly.A few more examples are the mudguards, cases forlaptop or i-phone and the handle of this knife, madefrom natural materials. Here we have driven theindividualization very far. The colors and patterns ariseby chance in the surface and emerge directly from thecasting process. Blade and clamp are fitted in the same

Produkte/ Accessoires

Spritzschutz - Schmutzfink

Laptopcases & Gehäuse

I-Phone-Cases

Messergriff

in the form of shocks or punches, inside it houses themost aggressive chemical substance, which can bepurchased legally: petrol without lead. A good proof,that biomaterials perform a lot.

Because 'biomaterial' is sometimes mistaken with 'bio-degradable', we have produced this tank for a racingmotorcycle. It consists of hemp fibre fabric and linseedepoxy, weighs just under 2kg, slightly lighter than athin aluminum tank and has to be extremely resistantinside and out. External mechanical influences come

Mobilität

NFK-Renntank im EinsatzFormenbau und Herstellung

do not have to hide since they can be very attractiveon the surface.

This development is a three-wheeled racer for the shelleco-marathon from team eco-emotion. A lightweight,made from 50% raw materials, it weighs, just like thedriver, about 50 kg. It is used as a long distanceendurance vehicle. A very beautiful example fortransportation engineering in which biomaterials just

Forschung und Entwicklung

Naturfaserverstärkte Karosserie und Chassis des Zero07 des Teams Eco-Emotion

an effort-and-benefit-calculation. more benefit we gainthrough:- Use of known and existing manufacturing technologies- Lightweight constructions and material efficiency- Functional integration- Transparent production methods

As biomaterials are still slightly more expensive, in thedesigning process we have to multiply functions andwith this the value of the object. It is not about tosubstitute a (in producting sense) low complex material,such as wood, by a complex natural composite. Whenbiomaterials come in range for use we have to make

- And at least individuality

• Bekannte Technologien• Leichtbau und Materialeffizienz Minimierung des Energieaufwandes bei der Herstellung, beim Transport

• Funktionsintegration Bauteile mit Mehrfachnutzen

• Transparente Fertigungmethoden Ablesbare Prozesse

• Individualität im Serienprodukt

---> Ziel: Höhere Akzeptanz von BiowerkstoffenPreisliche Unabhängigkeit

Mehrwert

Vielen Dank für die Aufmerksamkeit

Ernst-König Straße-206108 Halle/ Saale

Tel.:+49(0)345-775158040Fax:+49(0)345-775158001

http://www.mehrwerkdesignlabor.de