Tilly Tote.

1.1 CONTACT INFORMATION
Morgan Matt
Virginia Tech
1.2. SUBMITTING CATEGORY
Student
YES Autodesk Fusion 360
YES Aluminum
morganm8@vt.edu
(860)808-4563
302 North Main St.
Unit 4
Blacksburg, VA 24060
United States
2.1 PRODUCT TITLE AND DESCRIPTION
Tilly Tote.
Encouraging family gardening in order
to educate a new, cleaner generation
The Tilly Tote is a flat pack gardening kit built with a nutritious life-cycle and healthy lifestyle in mind.
The kit can be described as more than a sell-able product, but rather, a multifaceted educational program.
All of the included tools are designed to encourage family gardening in order to educate a new, cleaner generation. Growing and
learning activities are brought right to your backyard. Literally! In order to reduce packaging pollution, Tilly Tote was designed
with a specific constraint: to be wrapper and packaging free. The fabric of the bag itself is creased at specific folding points
in order to transform back and forth between tote and shipping envelope. The child’s name and shipping address are printed
with biodegradable ink directly onto the fabric, serving a functional use while giving the tote unique name personalization.
Upon arrival in the mail, 2D aluminum gardening tools are thoughtfully nested together, making a fun building activity for
the family! Specific perforations in the metal make for easy, one-time bending into 3D tool heads! Assembly instructions
can be found printed on plantable veggie seed paper. Once the tools and tote are constructed, the instructions can be
torn along the perforations and planted for some delicious, home-grown veggies! Gardening not only encourages healthy
nutrition, but teaches kids responsibility and cooperation; skills and knowledge needed in order to work towards a cleaner
generation, healthier lifestyle, and future.
2.1 PRODUCT DESCRIPTION
PRODUCT STORYBOARD
From User’s hands back to Earth
1. Tilly Tote arrives right to the user’s home through the mail!
2. On the backside of the mailer, overlock stitching can easily
be undone by snipping the end tab and pulling through.
5.
3.
3. The flaps can be unfolded to reveal a gardening kit inside!
Contents include:
printed seed paper instructions, 3 aluminum tool
heads, 3 aluminum rings, and 3 bamboo handles.
1.
The User can look to the seed paper for easy-to-follow
assembly instructions for each of the gardening tools.
4. The first step in assembly involves bending the tool
heads. The aluminum pieces are perforated along specific
fold lines, allowing an easy transformation from 2D to 3D.
1.
5. Separately the metal rings can be fit onto the threaded
extrusion of the bamboo handles. Once in place, the file
end of the tool head is inserted with a friction fit through
the metal ring and into the bamboo. The threaded ring
twists and locks to ensure the tool head stays in place.
4.
2.
6. Now that the envelope is empty, unfold remaining
flaps and flip the bag pattern over to the colored side.
7. The bag can then be assembled with three easy
folds and secured with the aligned bamboo buttons.
(Instructions can be found on the seed paper).
8. Fold the seed paper along the perforated lines and tear to
separate. (Each section has a different type of vegetable).
9. Sectioned seed paper can be placed in the soil
with new tools and watered thoroughly. With sun
and proper care, the family can reap the benefits
of fresh veggies right from their own backyard!
8.
6.
7.
9.
ECO-MANUFACTURING:
2.3. ILLUSTRATION OF PRODUCT’S SYSTEM
Renewable energy & Water stewardship
1.
Raw Material
7.
START
Recycled Aluminum
Soil
Bio-Nutrients
1.
Raw Material
Raw Material
Seed Harvest
Bamboo Harvest
Collection
2.. Maximizing Raw Material
All of the materials used to manufacture Tilly Tote are used to capacity, ensuring
that even cut-offs, residues, and by-products are not wasted. The soy bean in
particular, is used in several steps of the production line. While soy fiber from the
plant is used as feed for local sheep, (then used for felt), the extracted oils and
by-products are used to create soy ink (for printing instructions), soy fabric, soy
milk dyes (for coloring fabrics), and soy based adhesive for bamboo blanks
2.
Soy Feed
Soy By- Product
Vegetable & Flower
Sheep
Soy Milk Dye Mix
Production
Soy Fabric
Manufacturing
Soy Ink
Dye Fabric
Production
Blend Pulp & Seeds
Milled
Aluminum Rings
Technical
Nutrients
Up-cycled Aluminum
3.
Purified Effluent Water
The manufacturing process of fabric eliminates carcinogens and toxins upfront. Wool fibers are taken straight off the sheep with no post-processing
or dyes applied. After washing and needle punching, the water is healthy
enough to leave the factory. Meanwhile, soy inks off fabric production reach
a dual-tank designed to trap ink and emulsion solids before they reach
outflow. Such systems have been noted to potentially leave the water cleaner
than when it arrived. [ see #4 for the what water is reused in the system]
4.
Close-Looped System: Maximizing Natural Energy
A water-jet process is used to cut aluminum tool heads. No cooling or
lubricating oils are used, meaning there are no chemically contaminated
chips to dispose of. (The jet stream also allows nesting to maximize
material utilization) Water and abrasive can be reused several
times in a closed loop system with filtration. Likewise, the water used in
production of soy fabric can be filtered back and reused many times over
Tool Heads
Milled
Bamboo Tools
3.
Cut & Perforated
6.
Seed Paper
Fiber Reactive Dyeing
4.
Bamboo Plank
Production
5.
Shearing
Metal Sheets
6.
4.
Biological
Nutrients
To Soil
3.
Felt
5. Re-purposing “Waste”
After forming the bamboo blanks, the leftover shavings and pulp are
used to blend with veggie and flower seeds; then dried on racks to create
plantable paper (with soy ink instructions for assembly by consumer)
Instructions & Shipping
Manufacturing
Printed on Seed Paper & Tote
8.
1.
Die- Cut
Felt & Soy Fabric
Sourcing Local
Extraction of raw material is often the most carbon intensive process. The natural
materials for Tilly Tote are sourced from local farmers, therefore supporting
local communities and the environment. Sourcing locally, significantly reduces
fuel burned in transportation, encourages use of local farmland, reduces
chemical use for soil preservation, and creates overall fair working conditions
Sew
Bamboo Buttons
& Tote
Fold & Seal
Geothermal Heat & Recovery for Energy
Low heat from a geothermal drying kiln is used to dry the bamboo blanks and
plantable paper-resulting in lower emissions and energy costs to the company. Any
radiated or excess heat is captured [by waste heat to power (WHP) process] to
generate new energy; providing power to other processes such as die-cutting.
7.
Recycled & Up-cycled Aluminum
In acquiring aluminum in early production, the material can easily be recycled
from other products. Once Tilly Tote tools reach end of life, materials are taken
back to the supply chain to be reused and given equivalent value. [also
negating need for further virgin stock]
8.
Reduced Carbon Footprint
All parts of the product (tools, bag, instructions) are flat packed and delivered
straight to the consumer’s home; reducing carbon footprint in more than one way!
Tool Kit
Sew edges shut with
tools and seeds inside
Tilly
Tote
6.
Combine Bamboo &
Aluminum Parts
8.
Home Delivery
Re-Construct
Garden & Play!
De-construct
Separate Materials
Decompose
Veggies, Wool, Soy, &
Bamboo
3.0 REUTILIZATION CYCLE & BUSINESS MODEL
0.
1.
2..
3.
4.
5.
2..
3.
4.
5.
2..
3.
4.
5.
REUTILIZATION CYCLE
BUSINESS MODEL
Once Tilly tote has reached the end of its life, the
company will support a low priority postage system
in order to recover materials. A return shipping label
will have already been printed on the bag (on the
proper flap opposite from the consumer’s address).
[#0.] It is encouraged that the consumer repack the
materials in the bag with a simple overlock stitch
and place in their mailbox to be shipped back out!
Should the tote not be returned by mail,
materials can still be recycled by other means.
[#2.] [#2.] Separating bamboo and aluminum can
be done by simply untwisting the threading of the
aluminum ring and pulling out the tool head. [#2.]
Likewise, felt and soy fabric can be separated easily
by using scissors to undo the overlock stitching on the
boarder. [#3.] The wool, soy fibers, and bamboo are
100%biodegradable and would be broken down at
a local municipality-composting site. The non-toxic
soy/bio-dyes used on the soy fabric and thread would
naturally decompose as well, without harm to the
environment. [#4.] The bio nutrients returned back to the
soil would provide food for new soy seeds to germinate (as
well as bamboo) [#5.] Once harvested the soybeans could
be separated to provide oils for inks and feed for sheep!
[#5.] Wool grown on the sheep, by-products from the soy,
and bamboo could then be sent through the manufacturing
process once again to create more fabric and tools.
Where the raw materials are sourced from holds just
as much importance as Tilly Tote’s destination. All
materials used in manufacturing are to be sourced
from local Farmer’s, supporting the local economy and
environment. The product concept is heavily inspired
and influenced by the ever-growing Farm-To-Table
movement. As such, the business lives by the morals
and standards behind its culture, including sustainable
agriculture and the tight-knit link between customers
and farmers. Local jobs increase while the pollutants
sourcing raw materials are significantly reduced.
On the technical nutrient side, aluminum can be infinitely
recycled. [#3.] The tool heads can be dropped into
curbside ,public space recycling bins, or at local recycling
drop-off. [#4.] Once collected and crushed, the aluminum
will be melted into ingots. [#5.] In a rather short time
frame the aluminum can be used to make new products
or up-cycled to the manufacturing site to be used for
new tools! That means more Tilly Tote kits for gardening!
4.1 OVERVIEW:
Tilly Tote is designed with the environment in mind,
but more-so, to educate the people who share our
planet. From immediate arrival in the mail, the tote’s
disguise as packaging serves an important and
exciting lesson. User’s will grasp an understanding
for sustainability and the overuse of packaging, as
it is not needed at all with a little design intention!
The product’s main purpose as a gardening kit provides a
bonding experience for families and encourages outdoor
play. While caring for plants and collecting fresh veggies,
kids can learn about science, nature, personal nutrition,
and the importance of our surroundings. Helping kids
develop a love for nature and value for the environment
is a mission that lives in the heart of the Tilly Tote Brand.
Tilly Tote is made from six homogeneous materials. [1.]
The Eco-felt made from natural, untreated wool fibers
is completely biodegradable and provides structure
(and protection in shipping through mails) with thickness.
Wool holds many other beneficial features for gardening
since it is anti-bacterial, weather resistant, and sturdy.
[2.] Bamboo is a readily renewable resource that is cost
effective. (As a designer I was extremely determined to be
tree-free). The material is anti-bacterial, water-resistant,
and durable; all excellent traits for the tool handles.
[3.] Soy Fabric is made from the by-product of soy oils
(the hulls)- a plant particularly known for its many uses.
The plant is a renewable resource that can be grown
organically and maximized in use (as it is with animal
feed, ink production, and bamboo adhesive here). The
fabric is also anti-bacterial and safe to place veggies
in! [4]. Biodegradable ink used on the soy fabric and
plantable paper is readily absorbed producing beautiful,
bright, and readable color that’s safe for the environment.
[5.] A variety of vegetable seeds are used in the instructions
paper (with bamboo pulp and bio-ink) and go directly
into the soil to grow. [6]. Aluminum used for the tool heads
and rings can be readily resourced and infinitely recycled.
1.
4.
2.
5.
3.
6.
Tilly Tote.
Encouraging family gardening in order
to educate a new, cleaner generation
4.2. Material Reutilization:
5. Design with Autodesk’s Fusion 360™:
Tilly Tote bag is design for disassembly and uses 100%
recycled or renewable content. The whole product kit
has a Reutilization Score of 100, allowing the bag to be
eligible for platinum C2C certification
While it is extremely important to design in a physical
sense with sketching and rapid prototyping, Fusion
360 allows for a rapid, accurate, and easily altered
3-dimensional model. Although I had already developed
my idea through sketching and some cardboard mockups, the finer calculations for sizing and fittings for the
gardening tools came into play with Fusion. Being able to
type in numerical values made it possible to make minor
tweaks time and time again, finding the right ergonomic
dimensions for a child’s hands (based on anthropometric
data) while simultaneously working towards a model with
the “least amount of material needed”. Not only was
this a time-saver guaranteed for accuracy, but it meant
using less material in the long run for minor alterations.
The number of alterations I made on Fusion would have
ultimately added up to 20 foam mock-ups. Fusion made
is extremely easy to scan my drawings (and cardboard
models) and mold the handle 3-dimensionally to the
proper outlines. Making minor tweaks to an original mold
was far easier for me; someone who doesn’t have as
much success with entirely math based CAD programs.
I additionally used the 3D model of Fusion in order to
create perfect matching threading between the bamboo
handles and the aluminum ring attachments; getting
a perfect match was essential for the system to work.
Because the overall system is cloud-based, working in
a group would be much easier than a traditional (noncloud based) program. Components could be created by
members of the team and, most importantly, design ideas
could be easily and visually communicated to the group
from a distance. This would prove particularly beneficial
if sharing the online link with a manufacturer. Working
together to fit the tooling while maximizing nesting for their
machines could be edited by the manufacturer directly.
This would be important from a financial standpoint but,
more importantly, in minimizing waste. The handle and
ring here would need to be milled while the flat tool heads
would need to be water jet. Since I plan to seek investors/
crowdfunding for a prototype post competition, I’ll be using
(a version) of this Fusion CAD model for manufacturing!
4.3. Material Health:
Eco-Felt (Organic wool)
is not chemically treated during the entire production
process, from the farm to the finished garment or
product. The USDA National Organic Program
(NOP) has created strict standards for producing and
processing agricultural products to be sold as organic in
the US. In order to ensure that these standards are being
met, the NOP has accredited about 50 organizations
throughout the world as organic certifiers. Additionally,
the material is both Fire Resistant and Anti- bacterial.
[healthychild.com & msdsmanagement.com]
Aluminum
NFPA health score 0.”
Health-0
Flammability-0
Reactivity-2
Exposure-0
Storage-0
[www.flinnsci.com]
Bamboo
is a member of the grass family which has distinct
anatomical differences from wood. Therefore bamboo
would be regulated as an organic dust in a category
otherwise known as (PNOR) “Particulates Not
Otherwise Regulated, or Nuisance Dust by OSHA. The
only noted health hazard is in dealing with dust during
manufacturing- Bamboo is otherwise, a natural and
safe material.
[MSDS bamboo flooring]
Soy Fabric
is non-hazardous and is not classified as a Dangerous.
Traditionally many pesticides have been used for
cultivation, but organic soy can successfully be grown on
a smaller, more lower-impact scale (as used here).
[MSDS www.adm.com]
Bio-Degradable Dies
only use certified organic clays & vegetables (soy). These
dyes would be both safe for the user to interact with and
would be biodegradable.
[www.biodye.in].