3rd PLATE Conference
September 18 – 20, 2019
Berlin, Germany
Nils F. Nissen
Melanie Jaeger-Erben (eds.)
Universitätsverlag der TU Berlin
Ospina, Jose; Maher, Paul; Galligan, Anne; Gallagher, John; O’Donovan,
Dermot; Schischke, Karsten; Knorr, Stefan: Lifetime extension by design
and a fab lab level digital manufacturing strategy: tablet case study . In:
Nissen, Nils F.; Jaeger-Erben, Melanie (Eds.): PLATE – Product Lifetimes
And The Environment : Proceedings, 3rd PLATE CONFERENCE, BERLIN,
GERMANY, 18 – 20 September 2019. Berlin: Universitätsverlag der TU
Berlin, 2021. pp. 591 – 597. ISBN 978-3-7983-3125-9 (online). https://doi.
org/10.14279/depositonce-9253.
This article – except for quotes, fi gures and where otherwise noted – is
licensed under a CC BY 4.0 License (Creative Commons Attribution 4.0).
https://creativecommons.org/licenses/by/4.0/.
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3rd PLATE 2019 Conference
Berlin, Germany, 18-20 September 2019
Lifetime Extension by Design and a Fab Lab Level Digital
Manufacturing Strategy: Tablet Case Study
Ospina, Jose (a); Maher, Paul (a); Galligan, Anne (a); Gallagher, John (b); O’ Donovan, Dermot (b);
Knorr, Stefan (c); Schischke, Karsten (d)
a) MicroPro, Gommern, Germany
b) Galway-Mayo Institute of Technology – Letterfrack Campus (GMIT Letterfrack), Galway, Ireland
c) Designing Berlin, Berlin, Germany
d) Fraunhofer IZM, Berlin, Germany
Keywords: Eco-design; Circular Economy; Digital Fabrication; Manufacturability; Decentralized
Business Model.
Abstract: MicroPro Computers, an Irish SME working in the design and manufacture of computer
equipment based on circular economy principles over the past 20 years, is successfully
manufacturing a long-life miniature computer (the iameco D4R tablet), which addresses the three key
areas of product design, manufacturability and sustainable business model. These factors are
interlinked, and all are crucial to bringing the product to the market: A major barrier for local
production of sustainable IT is the inherent complexity of mobile electronics, so innovative
approaches are required to enable small-scale production. As part of the SustainablySMART Project,
(H2020 – FoF) MicroPro is working with GMIT Letterfrack and Designing Berlin, to adapt the design of
a green tablet, the iameco D4R tablet, for digital design and manufacture, using equipment typically
found in a FabLab or similar non-commercial manufacturing environment. Combining a localized
smart design and manufacturing approach with robust green credentials will allow for higher margins,
as well as flexibility in terms of production numbers and costs, and provide a replicable production
and business model for the green electronics sector
Introduction
MicroPro proposes a ‘regenerative design’
paradigm, that will ultimately give rise to the
following:
• A reduction in the consumption of raw
materials by using renewable
materials and by extending the use
lifetime of products and components
• A reduction in the generation of e-
waste because of a) longer life and b)
ease of recycling
• A reduction in the consumption of
energy during manufacturing and
during useful life
There are indications, that combing a localized
manufacturing approach with robust green
credentials which will allow for higher margins,
and more flexibility when it comes to
manufacturing costs. Euromonitor International
published a report in 2012 (Euromonitor, 2012)
which indicated a significant shift in consumer
behaviour towards more environmentally
friendly products. Factors such as climate
change, health awareness and environmental
issues, are influencing consumers to
reconsider the most important factors guiding
their purchasing decisions. Nearly 70% of
respondents across the globe said they were
‘somewhat to very willing’ to spend more on a
green product, compared to the same product
without green features.
MicroPro Computers has a long history of
design and manufacture of computer
equipment based on sustainable and circular
economy principles. This design strategy has
been developed over the past 20 years and
include the design and manufacture of iameco
desktop and laptop computers. These case
studies are well documented in previous
articles and reports. However, despite
successful prototype development, and some
small-scale sales, it has been impossible to
sustain the production and marketing of these
computers, due to the high costs associated
with outsourcing design changes and
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Schischke K.
Lifetime extension by design and a fab lab level digital manufacturing
strategy: tablet case study
manufacture of computers. The conclusion is
that small-scale, localised design, production
and marketing of innovative computers if
dependent on outsourcing design and
manufacture, proves financially unviable
MicroPro is currently participating in the
SustainablySMART project with the express
intention of developing a new approach to
design and manufacture, based on localised
digital design and manufacture, that could
make commercialisation of its ecological
computers viable.
Eco-Design Principles
MicroPro has developed, designed and
manufactured a number of prototypes for
desktop, laptop and more recently tablet
computers over the past 20 year. Through
these practical experiences, MicroPro
developed a comprehensive and proven eco-
design approach, which included a range of
elements, relating to design, choice of
materials, parts and components, and post-
sale services to customers.
MicroPro’s aim is to reduce environmental
impact not only “in operation”, but over the
entire lifecycle of the product. Both the iameco
V3 desktop and the D4R laptop were
manufactured primarily mainly from wood and
recycled materials. The D4R Laptop was
estimated to have 66% less CO2 emission,
use 65% less fresh water in manufacture, and
use 87% of materials that could be reused or
recycled, with respect to equivalent
commercial laptops.
Maximising reuse and extending
operational life
In addition to the environmental gains made by
selection of materials and components, a key
circular economy strategy is design for
upgrading and for ease of repair and for reuse.
Iameco computers are designed to be easily
disassembled using tools commonly available.
This enables quick and affordable repair,
upgrading and also the reuse of the housing,
parts and components. This design strategy
has been applied to all models. The
disassembly of the iameco v3 desktop, for
example, could be carried out in 11 seconds
using conventional tools. The design allowed
for flexibility in the repair and replacement of
parts and components. The D4R laptop
included a generic “universal motherboard”,
that allowed diverse components to be
connected to it. The housing was designed to
accommodate some variation in the size and
shape of new components.
Additional eco-design considerations
As partner in the SustainablySMART Project,
MicroPro has undertaken the design and
manufacture the iameco D4R tablet, based on
findings from its previous models. MicroPro
also undertook to scope the possibility of
design for reparability by repair shops and on
a DiY basis, of design for longevity of wear-
prone components (such as the battery), of
design for reliability and design for robustness.
MicroPro aims to achieve ease of manufacture
by developing a design that is appropriate for
manufacture in a digital fabrication
environment, accessible to SMEs or in Fab
Labs, by practically testing the
manufacturability in a semi-industrial
environment
Design iterations for the iameco
D4R tablet
The iameco D4R tablet has been developed
through a series of design iterations:
Iteration 1: The Alpha Prototype (AP)
The AP is designed to incorporate all of
MicroPro’s eco-design principles of
upgradability, updateability, reusability,
repairability, recyclability, ease of disassembly,
long life and elimination of most plastics. The
AP embodies these principles and is designed
to anticipate future changes of components, so
the chassis can be used again and again and
have different lives. It has also been designed
so that the mainboard and ancillary
components can be replaced using simple
tools. Use of glues or plastics other than those
embedded in essential components were
reduced where possible. The housing was
screwed together using standard Phillips type
screws. Design ensured natural ventilation and
prevents overheating. Connectivity is
maximised. The wooden frame provides a
protective standoff for the display. A kill switch
is provided for Bluetooth, Wi-Fi, microphone
and camera enhancing security. The AP is
manufactured primarily from maple and has an
interior aluminum frame for robustness and
stability. The AP is fully functional and
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Schischke K.
Lifetime extension by design and a fab lab level digital manufacturing
strategy: tablet case study
manufactured to a high specification. It
exceeds Project requirements by providing
fully functional electronics. Assembly of the
electronics was carried out in-house by
MicroPro. The manufacture was outsourced to
a commercial engineering workshop that uses
digital design and CCR manufacture.
Commercial outsourcing was an intermediate
step in the process, aimed at ensuring that the
AP was correctly manufactured, and that
drawings, specifications and assembly were
accurate and fit for purpose. The AP was not
the definitive prototype but aimed at providing
a baseline for further design improvements of
the housing, frame and electronic design, as
well as manufacturing strategies, which have
been the basis of subsequent iterations.
Figure 1. CAD drawing of the AP.
Iteration2: The Beta Prototype (BP)
The BP is designed and manufactured using
the AP as baseline. Development took place
from March to September 2017. The
manufacture of a 2nd prototype was not
originally envisaged in the project, but
subsequently agreed by the consortium. It has
proven to be a valuable way of progressing the
final design. For the sake of continuity,
MicroPro employed the same prototyping
company to produce the BP as produced the
AP.
The main aim of the BP, was to iron out design
short comings in the AP. MicroPro improved
the AP design by streamlining the wooden
housing and the aluminum chassis making the
device less bulky and appealing, lighter,
thinner and more robust. A new sliding back
cover was introduced (without screws or
fasteners) for ease of access for removable
battery, and a fingerprint sensor There was
also a material change of the seal-inlay to cork
to reduce moisture and dust penetration.
Additional ventilation holes were added to
maximise the life of the battery and electronic
parts and the number of parts overall was
reduced (simplification).
The BP aimed at providing an improved
template for design fabrication, leading to the
production of the Kappa Prototype.
Figure 2. The Beta Prototype.
Iteration 3: The Kappa Prototype (KP)
The KP was designed and manufactured using
the BP as baseline. It was developed from
September 2017 to March 2018. The
manufacture of the KP, the 3rd iteration of the
iameco D4R tablet, was also not originally
envisaged in the project, but likewise proved a
practical and effective method for arriving at
the final design.
The KP incorporates all of MicroPro’s eco-
design principles of upgradability,
updateability, durability, reusability,
repairability, recyclability, ease of disassembly,
long-life, carbon capture and elimination of
most plastics. By using a wooden chassis
instead plastic it not only incorporates carbon
capture (carbon from our time) but allows us to
modify and change the chassis. The KP is
designed to anticipate future changes of
components, so the chassis can be used again
and again and have many different lives. It has
also been designed so that the mainboard and
ancillary components can be replaced or
repaired using simple tools. The battery can be
replaced in 30 seconds.
Use of glues or plastics other than those
embedded in essential components have been
successfully avoided. The housing is screwed
together using 4 x standard Phillips type
screws. Design ensures natural ventilation and
prevents overheating. Connectivity is
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Ospina J., Maher P., Galligan A., Gallagher J., O’Donovan D.; Knorr S.,
Schischke K.
Lifetime extension by design and a fab lab level digital manufacturing
strategy: tablet case study
maximized. The wooden frame provides a
protective standoff for the display.
The KP is manufactured primarily from walnut
and has an interior recycled aluminum frame
for robustness and stability. The KP is fully
functional and manufactured to a state-of-the-
art electronics specification. Assembly of the
electronics was carried out by MicroPro in-
house. Re-design and manufacture of the KP
was carried out by MicroPro and GMIT in the
university’s own engineering workshop, using
CAD design and computer-controlled routing,
and has ensured that final drawings,
specifications of housing and frame are fit for
purpose. The metal frame is being
manufactured in Designing Berlin’s own
facilities.
Design improvements to the KP
Design for Manufacturability
The AP and the BP were designed and
manufactured by a commercial prototyping
company under MicroPro’s direction. These
prototypes were designed in CAD and the
CAD files of both were provided to GMIT
Letterfrack for review, in order to assess the
ability to machine the prototype on the Homag
CNC at GMIT campus.
GMIT Letterfrack has introduced the concept
of Design for Manufacture (DFM) that is the
practice of designing products with
manufacturing in mind. Embedding this
principle will allow for simpler manufacturing,
assembly and/or design of the proposed
product with the aim of reducing waste and
minimising production costs.
The correct implementation of DFM will lead to
reduced manufacturing costs, reduced lead-
time and improved quality. DFM should also
help to minimise waste and maximise yield
from raw materials, which lowers production
costs as timber waste from production is not
recoverable for re-use. DFM is an important
consideration when working under the
Ecolabel logo, which considers products from
the extraction of the raw materials, to
production, packaging and transport, right
through to your use and end of life. Not all
DFM principles are applicable to all production
of the iameco D4R tablet. Currently, these
principles can only be related to the
manufacture of the wooden housing and the
metal frame, but not the electronic or metal
components, which are sourced from external
suppliers, over which MicroPro has little or no
control.
Figure 3. BP wooden frame interior Section.
Choice of Materials for the KP
MicroPro’s preference from the start was for
solid wood. This was guided by an initial
survey of customer preference undertaken at
the start of the project. In selecting the wood,
the following considerations were taken into
account:
• Use a species with closed grain (e.g.
maple or beech)
• Use timber with straight grain, free of
knots and defects
• Grain direction should be
perpendicular to surface to minimise
movement (radially cut)
• Reduce moisture content to maximum
10% (to minimise distortion in service)
• To deduce tendency of cupping in
service, it may be worth using glued
strips of solid wood.
It was also considered important to use ethical
procurement when specifying timber materials.
Only timber from certified sustainably
managed forests would be used. Forest
Stewardship Council (FSC) and Programme
for the Endorsement of Forest Certification
(PEFC) schemes are those most recognised
for ensuring chain of custody of sustainably
sourced forest material. It would also be
possible to use off-cuts from the furniture
industry and second life woods, although these
were not used in any of the prototypes
produced. MicroPro decided to use walnut as
the material for the Kappa as it has a deep
lustre and warm and attractive grain.
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Schischke K.
Lifetime extension by design and a fab lab level digital manufacturing
strategy: tablet case study
KP Wooden Frame Design n
The design of the wooden frame for the KP
was based on an analysis by GMIT of the
frames design and produced for the AP and
the BP. This phase involved detailed design
work on the wooden chassis, aimed at
simplifying the design in order to reduce the
tooling complexity and time required.
Multiple design changes were required for the
KP to adapt it to manufacture in a Fab lab
environment. This is explained in detail in the
paper produced by MicroPro for the Going
Green Electronics Conference in February
2019, so will not be repeated here
Further consideration and research
Originally, the BP prototype took a total of 163
minutes approx. to machine on the CNC, with
the iterations to the KP design this has been
reduced to a total of 118 minutes. The sanding
of the Beta was estimated to be 180 minutes
due to the difficult areas to reach. The
redesigned elements of the KP reduced the
sanding process to 90 mins approx., depending
upon individual grain pattern and species
selection. The lamination process that created
the blank was done by manual clamping and
therefore does not provide an accurate
estimate on the time it requires to produce in
batched or higher quantity production runs.
However, the time it took to dimension, plane,
and finally calibrate the blank manually was
about 75 minutes per blank.
This is a total of 283 minutes for creating the
KP’s unfinished wooden chassis (based on a
production of a single unit). This brings the total
time of wooden chassis in its current form to
308 minutes with a water-borne lacquer finish.
This will be further improved and reduced in the
implementation of the Small, Batch production,
which is currently underway.
Metal frame design and
manufacture
Metal Frame design improvements
The metal frame from the AP and the BP were
designed and produced by commercial
prototypes, who had access to the required
manufacturing equipment. The initial KP frame
was also produced in this way. The production
of frames in this way would not be commercially
viable for marketing the tablet.
The BP metal frame (produced commercially)
however had to be modified at GMIT to match
changes in the wooden frame and the
electronics. Initially this was achieved by
designing and printing a re-designed frame in
plastic. The frame was then manufactured
commercially for the first KP version.
Fortunately, for the Small Batch Production
(explained below) MicroPro identified a metal
designer and fabricator who had been working
with Fab Lab Berlin, Designing Berlin. After a
meeting a partnership was formed, and
Designing Berlin went on to review and improve
the metal frame design and manufacture it.
The overarching four objectives in the redesign
of the metal frame: reducing the weight of the
metal frame, reducing the visibility of the
frame, improving its modular and upgradable
features and simplifying the manufacture, to be
adapted to typical Fab Lab equipment.
Additionally, updated electronics had to be
integrated. The final objective involved fixing
the new electronic components onto the
surface plate to identify the precise location of
the relevant components. The results were
then fed back to the 3D model of the revised
KP design.
An updated electronics setup allows the frame
to be visually narrower than the initial KP
version (which was a design objective). The
main reason for that is a different mounting
method for the touchscreen and the actual
screen.
In order to keep the CNC machining of the part
simple, all features can be machined with
basic 3 axis CNC machinery from only 2 sides.
The required side cut-outs for the connectors
are turned into independent, modular parts.
Otherwise they would require 5 axis machining
or 3 axis machining from 4 more sides
Various modular parts are mounted in the
actual frame and can be exchanged without
screws. In case future electronics offer new
interfaces, the modular frame parts can be
redesigned accordingly and exchanged along
with the electronics. The mainframe stays as it
is.
The weight reduction of the frame is improved
by adding several triangular shaped holes, that
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Lifetime extension by design and a fab lab level digital manufacturing
strategy: tablet case study
results in a thin wall, lightweight frame. Where
the user touches the tablet, that strategy would
result in a strange haptic as well as dirt
attracting surface. Those areas have only one
long cut-out with nicely filleted transitions. The
final weight is about half of the KP version,
roughly 150g.
Figure 4. New metal frame for the KP, improved
by Designing Berlin.
Figure 5. Detail of material reduction design in
KP Metal Frame.
Small batch manufacture of the D4R
tablet
Towards the end of the SustainablySMART
Project (May – October 2019), MicroPro and
Project Partners took a further step in
advancing the commercialisation of the D4R
Tablet, by sampling a small batch manufacture.
This involves the production of 30 working units
of the Tablet, that will be tested and certified by
Grant4 Com to demonstrate compliance with
EU market regulations. For this final step,
MicroPro is carrying out the entire design and
production process working with FabLab
equivalent bodies. For this to happen, it was
necessary to identify an additional non-
commercial contractor that would review and
improve the metal frame design and produce
the 30 frames for the proposed small batch.
With the help of Reuse-IT (Berlin), a Berlin
FabLab maker, Stefan Knorr (trading as
Designing Berlin) was identified as having the
necessary skills and equipment, but also
commitment, to work on the project and
produce the required metal frames for the initial
small batch. The wooden frame would be
reviewed, improved and manufactured by GMIT
Letterfrack, and the electronic components
would be improved, sourced and assembled by
MicroPro.
This final review of the metal frame design led
to overall design improvements in the final
version. The weight of the metal frame was
reduced by around 50%, and a number of
operating details improved. The review of the
design of the wooden frame design by GMIT
also resulted in some improvements and
required a re-calibration to take the new metal
frame into account, as well as improved
electronics. The electronic design was also
upgraded, to encompass the ever-rising
standards of computer components on the
world market and need for improved multi-
functionality from the initial Kappa design.
Evaluation of the D4R tablet
In order to gain added value from the sample
small batch manufacture, MicroPro and
Partners decided to undertake a Customer
Evaluation exercise, to be rolled out during the
final three months of the SustainablySMART
Project (August, September and October 2019).
This will involve the identification of a number of
private companies, universities and public
computer outlets in some Partner regions, who
will carry out a short evaluation of actual D4R
Tablets, for a limited period of time. These
agencies will collect consumer information and
feed it back to MicroPro, aimed at establishing
customer reaction to the product.
The Key target groups that will be targeted are:
- Private companies with an interest in
ecological products
- University students and lecturers
- The general public
A number of agencies have been identified for
the Evaluation exercise that are representative
of, or able to access the 3 Target Groups in a
number of Partner regions. The Questionnaire
and interviews proposed aim to secure the
view of potential users regarding the design,
materials, weight, functionality and pricing of
the tablet.
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Lifetime extension by design and a fab lab level digital manufacturing
strategy: tablet case study
A viable design and manufacturing
strategy
A main objective in the SustainablySMART
project has therefore been to demonstrate that
digital fabrication in a local, non-commercial
digital fabrication workshop is a potential
solution to the viability challenges so far
encountered.
The use of digital design and fabrication per se
does not generate viability, and indeed
commercial prototype developers already
employ digital design and fabrication as a
method for producing prototypes (for example,
the company that produced the original AP
and BP models was a commercial prototyping
company using digital fabrication). But this
company would not be able to manufacture the
final prototype at a commercially viable price.
The final stage of the SustainablySMART
Project, and in particular the Small Batch
Production, has demonstrated that it is
feasible to design and manufacture a fully
operational state of the art tablet within SME
and FabLab equivalent facilities, as long as
non-commercial associates with the right
equipment, skills and attitude are identified.
This allows the SME to achieve some
relaxation of the tight financial constraints that
limit commercial outsourcing.
The partnership composed of MicroPro, GMIT
Letterfrack and Designing Berlin have proved
the viability of the model with the
implementation of a small batch production
(30 units) of the iameco D4R tablet The
assembly of this Team has been central to
making this non-commercial process viable
and could be the main basis for future
manufacture of the iameco D4R Tablet. Also, it
demonstrates that a more decentralized model
for manufacture, repair, upgrading and
production of the tablet, as described in part 7
above.
The SustainablySMART Project has been
successful in demonstrating that locally based
non-commercial digital design and fabrication
can be the basis for more viable manufacture
of iameco D4R tablet and possible other
iameco models.
We believe this is a major step forward in
making sustainable computer manufacture a
possibility.
This project has received funding
from the European Union’s Horizon
2020 research and innovation
programme under grant agreement
No 680604
