foto
a p lay c amer a t hat imp roves
on t he su s t ainabili t y of mo d ern
p las t ic and e le c t ronic toy s .
1 .1 C ont ac t Informat ion
1 . 2 Submit t ing C ate gor y
A b by J et mund sen
V irginia Te ch
U ni ted St ates
Stu den t
Use d Fu sion 3 60
2 .1 Pro duc t D escrip t ion
2 . 2 Image
Each year, over 40 million toys are
thrown away. The vast majorit y of today’s
toys aren’t designed to be taken apar t or
recycled, and as a result, most of them
ultimately end up in landf ills.
I set out to discover how toys could be
made more sustainably. As a case study,
I decided to focus on elec tronic toys–
these are of ten some of the most dif f icult
toys to take apar t and recycle.
electronic toys are of ten full of
tangled wires and sharp metal
p a r t s , w h i c h c a n m a ke t h e t a ke
apar t process feel intimidating.
Foto is a toy camera that uses upcycled
components, recycled materials, and
that carefully considers the end of life
disposal process.
During it s life, Foto is a fun, durable
camera toy that takes real photos and
encourages ac tive play.
At the end of Foto’s life, users can
easily separate the produc t ’s elec tronic
component s from it s plastic shell.
The elec tronics are contained as single
unit, and are addressed and stamped like
an envelope. They can be dropped into
any mailbox and will be delivered to the
appropriate recycling facilit y.
The toy’s ex terior is made from recycled
HDPE plastic and as a result, can be
placed into any standard home recycling
bin.
P r o c e ss
2 . 3 Illus t rat ion of t he p ro duc t ’s s ys tem + 3 .1 Reu t ilizat ion c ycle
1
2
M a t e ri a l S o u r ci n g
M a n u f a c t u ri n g
D i s t ri b u t i o n
Plastic milk jugs and bot tles are
co l l e c t e d f r o m r e c y c l i n g p l a n t s .
Plastic par ts are molded from recycled
HDPE material. Paperboard material is
c u t a n d f o l d e d t o c r e a t e b oxe s . S o y i n k
l a b e l i n g i s p r i n t e d o n e a c h b ox . C i r c u i t
b o a r d s a r e p r o d u ce d u s i n g a n a d d i t i v e
technology in order to signif icantly
d e c r e a s e w a s t e a n d c h e m i c a l u s e [1 ] .
A l l m a te r i a l s a n d p a r t s a re s o u rce d a n d
f a b r i c a te d i n t h e U S to re d u ce t h e a m o u n t
o f e n e r g y n e e d e d to t r a n s p o r t e a c h p ro d u c t .
Camera lenses are upcycled from
old Android smar t phones.
P a p e r i s s o u r ce d f r o m r e c y c l i n g
plants to create paperboard.
3
Soybeans are grown and
har vested to create soy ink.
Fiberglass resin and elec trical wire
are sourced from socially fair and
sustainable manufacturers in the US.
5D
Use
4
F o t o i s n o n - t ox i c , d u r a b l e a n d b u i l t t o l a s t .
The toy disassembles into four par ts, which
c a n e a s i l y b e r e p l a ce d i f t h e y w e a r o u t .
E n d o f Li f e – L a b e l i n g + D i s a s s e m b l y
5A
E n d o f Li f e – Re c ycl i n g E l e c t r o n i c s
li f e cyc le
W h e n u s e r s p u t b a t t e r i e s i n F o t o, t h e y
s e e c l e a r, e d u c a t i o n a l l a b e l i n g t h a t
e n co u r a g e s t h e m t o s e p a r a t e t h e t o y
a n d r e c y c l e e a c h p i e ce p r o p e r l y.
A t U R T, t h e p a p e r b ox i s c o m p o s t e d .
The component s and wires are
detached from the circuit board. The
board is shredded, and the f iberglass
a n d m e t a l p a r t i c l e s a r e s e p a r a t e d . [ 2]
Metals reclaimed from the shredded
circuit board, elec trical wire, and
component s can be smelted for
r e u s e. P l a s t i c s r e c l a i m e d f r o m t h e
elec trical wire and component s can
be recycled. The f iberglass dust
can be used in the creation of new
b u i l d i n g m a t e r i a l s , l i ke c o n c r e t e. [ 3 ]
E n d o f Li f e – M a i l i n g E l e c t r o n i c s
E n d o f Li f e – Re c ycl i n g Pl a s t i c s
F oto’s e l e c t ro n i c co m p o n e n t s a re co n t a i n e d
i n a p re - a d d re s se d , p re - s t a m p e d b ox . Th e
b ox i s m a i l e d to a US f a ci l i t y l i ke U n i ve r s a l
Re c ycl i n g Te ch n o l o g i e s ( U RT ) i n W i sco n s i n
fo r p ro p e r d i s a s se m b l y by p rofe s s i o n a l s .
A t t h e e n d o f i t s l i f e , F o t o’s p l a s t i c
p i e ce s c a n b e p l a ce d i n a s t a n d a r d
h o m e r e c y c l i n g b i n . O n ce r e c y c l e d , t h e
material can be ground up and reused
a g a i n t o m a ke o t h e r p l a s t i c p r o d u c t s .
5C
[1 , Neilson] , ht tps: //goo.gl / Whp8Uo
[2, E -Was te Shredding] , ht tps: //goo.gl /6EC53Y
[ 3, Kakimoto] , ht tps: //goo.gl / IjT ZtC
5B
3 . 2 B usiness mo del
F o to a p p e a l s to p a re n t s a n d d i f fe re n t i a te s i t s e l f f ro m co m p e t i to r s
by e n co u r a g i n g k i d s to e n g a g e i n a c t i ve p l ay a n d s p e n d t i m e
aw ay f r o m s cr e e n s . T h e b a c k o f t h e toy fe a t u re s a n e - i n k d i s p l ay
t h a t s h o w s t h e n u m b e r o f p h o to s l e f t . T h i s s i g n i f i c a n t l y i n c re a s e s
b a t te r y l i fe a n d e n co u r a g e s k i d s to b e i n t h e m o m e n t w h e n
t a k i n g p h o to s . W h e n k i d s a re re a d y to l o o k a t t h e i r i m a g e s , t h ey
c a n u s e b l u e to o t h to co n n e c t F o to to a t a b l e t o r p h o n e.
F o to’s u s e o f u p c yc l e d a n d re c yc l e d m a te r i a l s w i l l a l l o w t h e toy
to b e s o l d a t a co m p e t i t i ve p ri ce.
F o to’s c l e a r, a p p ro a c h a b l e d i s a s s e m b l y a n d re c yc l i n g p ro ce s s
t e a c h e s co n s u m e r s a b o u t t h e i m p o r t a n ce o f s u s t a i n a b i l i t y, a n d
a l s o r a i s e s aw a r e n e s s a b o u t t h e n e e d f o r m o re s u s t a i n a b l e
p ro ce s s e s a n d p ro d u c t s i n t h e toy i n d u s t r y.
A s co n s u m e r s b e co m e m o re aw a re o f t h e n e e d f o r m o re
s u s t a i n a b l e toy p ro d u c t s , t h e re w i l l b e a n i n c r e a s e d m a rke t
d e m a n d f o r toy s a n d e l e c t ro n i c p ro d u c t s w i t h a s u s t a i n a b l e
f o o t p r i n t . T h i s w i l l p re s s u re o t h e r toy co m p a n i e s to a d o p t m o re
s u s t a i n a b l e p r a c t i ce s a n d l e a d to a n i n c r e a s e i n a cce s s i b l e
r e c yc l i n g p r o g r a m s .
U l t i m a te l y, F o to w i l l h e l p ke e p p l a s t i c a n d e l e c t ro n i c p ro d u c t s
o u t o f l a n d f i l l s a n d w i l l h e l p i m p r ove t h e h e a l t h o f t h e p l a n e t .
4 .1 M aterial sele c t ion over v iew
4 . 2 M aterial reu t ilizat ion
Foto is made from f ive homogeneous materials:
F o t o i s n e a r l y 1 0 0 % r e u s a b l e. T h e H D P E p l a s t i c co m p o n e n t s a r e f u l l y
r e c yc l a b l e a n d c a n b e p r o ce s s e d t o m a ke n e w p l a s t i c m a t e r i a l .
H i g h D e n s i t y Po l ye t hy l e n e i s o b t a i n e d f r o m r e c y c l e d
p l a s t i c b o t t l e s a n d i s u s e d t o f o r m t h e t o y ’s o u t e r
b o d y a n d t o m a ke p a r t o f t h e e l e c t r o n i c c o m p o n e n t s .
1 0 0 % r e c yc l e d p a p e r b o a r d i s u s e d t o c r e a t e a
c o n t a i n e r f o r t h e t o y ’s e l e c t r o n i c s .
S oy - b a s e d i n k i s u s e d t o p r i n t t h e i n s t r u c t i o n s ,
postage, and recycling address on the paperboard.
F i b e r g l a s s i n f u s e d w i t h s m a l l a m o u n t s o f m e t a l ( l i ke
g o l d , s i l v e r, a n d c o p p e r ) i s u s e d f o r t h e c i r c u i t b o a r d .
I n s u l a t e d co p p e r w i r e i s u s e d t o c o n n e c t t h e
elec tronic component s to the circuit board.
[1 , Kakimoto] , ht tps: //goo.gl / IjT ZtC
T h e c i r c u i t b o a r d ’s p a p e r b o a r d c o n t a i n e r a n d p r i n t e d s o y i n k l a b e l i n g
a r e f u l l y co m p o s t a b l e.
T h e c i r c u i t b o a r d i s i n t e n d e d t o b e s e n t t o a s p e c i a l i ze d r e c yc l i n g
f a c i l i t y, s u c h a s U n i v e r s a l Re c y c l i n g Te c h n o l o g i e s i n J a n e s v i l l e ,
W i s co n s i n . T h e r e , t h e r e m a i n i n g m e t a l , p o l y m e r, a n d f i b e r g l a s s
materials are separated by machines and professionals.
T h e f i b e r g l a s s i s s h r e d d e d a n d p r o d u ce s a d u s t t h a t c a n b e u s e d i n
t h e c r e a t i o n o f n e w b u i l d i n g m a t e r i a l s , l i ke co n c r e t e [1 ] . T h e m e t a l s
c a n b e s o r t e d o u t f r o m t h e f i b e r g l a s s p a r t i c l e s a n d s m e l t e d f o r r e u s e.
The elec trical wire can be stripped, separated into its plastic and
m e t a l p a r t s , a n d f u l l y r e c yc l e d . S m a l l p o r t i o n s o f s o m e e l e c t r o n i c
co m p o n e n t s m a y n o t b e a b l e t o b e r e c y c l e d , b u t t h e m a j o r i t y o f
material would be able to be reused.
you can ship
a ny c o n t a i n e d
object in the
US mail if it has
an address and
postage.
reutilization
s co r e
( 7 5* 1 ) + (9 0 * 2)
3
=
85
Foto uses
7 5% r e c y c l e d
material and is
90% recyclable
or compostable.
4 . 3 M aterial heal t h
H i g h D e n s i t y Po l ye t hy l e n e
b i o l o g i ca l l y i n e r t , N F PA h e a l t h sco r e 0
H D P E p l a s t i c s a re u s e d ex te n s i ve l y i n f o o d p a c ka g i n g
a n d o t h e r co n s u m e r p ro d u c t s . T h ey ’re n o n - tox i c a n d
s a fe f o r u s e i n c h i l d re n’s toy s . [1 ]
Re c ycl e d p a p e rb o a r d
n o n - tox i c a n d b i o d e g r a d a b l e, N F PA h e a l t h sco r e 0
T h i s p a p e r b o a r d i s m a d e co m p l e te l y f ro m re c yc l e d
p a p e r, a n d i s a l s o 1 0 0 % re c yc l a b l e i t s e l f. I t c a n b e
d i s p o s e d o f u s i n g a h o u s e h o l d p a p e r re c yc l i n g s y s te m
o r co m p o s t i n g s y s te m . [ 2]
S oy - b a s e d i n k
n o n - tox i c a n d b i o d e g r a d a b l e
S oy i n k i s m a d e f ro m s oy b e a n s , w h i c h a re a re n ew a b l e
re s o u rce. A s s oy b e a n s g ro w, t h ey a l s o h e l p to re m ove
c a r b o n d i ox i d e f ro m t h e a t m o s p h e re. S oy i n k i s s a fe
a n d l o w - co s t , a n d t h e p ro d u c t i o n p ro ce s s d o e s n’ t l e ave
b e h i n d a ny h aza r d o u s w a s te. [ 3]
5 .0 D esigne d w it h Fu sion 3 6 0
Fi b e r g l a s s l a m i n a t e
n o n - tox i c , n o n - h aza r d o u s
T h e s o l i d f o r m o f t h i s f i b e r g l a s s l a m i n a te i s n o n - tox i c
a n d n o n - i r r i t a b l e, a n d i s m a d e f ro m p a p e r, re s i n , a n d
co p p e r. O n ce t h e c i rc u i t b o a r d i s g ro u n d i n to d u s t f o r
re c yc l i n g , t h e d u s t p a r t i c l e s m ay a c t a s a n i r r i t a n t a n d
s h o u l d b e h a n d l e d w i t h c a re by p ro fe s s i o n a l s . T h i s
l a m i n a te e n c a p s u l a te s t h e c i rc u i t b o a r d b a s e a n d s m a l l
d e p o s i t s o f m e t a l . T h e m e t a l s c a n b e f i l te re d o u t f ro m
t h e l a m i n a te o n ce t h e m a te r i a l i s i n d u s t f o r m . [4]
C o p p e r w i r e ( i n s u l a t e d w i t h m PPE )
n o n - tox i c , n o n - h aza r d o u s
C o p p e r e l e c t r i c a l w i re i s u s e d to co n n e c t t h e e l e c t ro n i c
co m p o n e n t s to t h e c i rc u i t b o a r d . T h e w i re i s co a te d w i t h
m o d i f i e d p o l y p h e ny l e n e e t h e r (m P P E ) , a n e co - f r i e n d l y
a l te r n a t i ve to t r a d i t i o n a l P VC co a t i n g s . T h i s w i re i s n o n tox i c a n d h a s m i n i m a l e nv i ro n m e n t a l i m p a c t . T h e co p p e r
a n d co a t i n g c a n b e e a s i l y s e p a r a te d a n d a re b o t h 1 0 0 %
re c yc l a b l e. [ 5 ]
A
5
1
4 2,3
B
A f te r c re a t i n g ro u g h i n i t i a l m o d e l s w i t h p a p e r a n d f o a m ,
I u s e d Fu s i o n 3 6 0 to f i g u r e o u t t h e p r e ci s e d e t a i l s o f
my d e s i g n a n d re a l l y b ri n g F o t o t o l i f e.
M o d e l i n g m y d e s i g n i n Fu s i o n 3 6 0 h e l p e d m e to m a ke
s u re t h a t a l l o f m y p ro d u c t ’s p a r t s w o u l d f i t t o g e t h e r
m e c h a n i c a l l y a n d l o o k ri g h t v i s u a l l y. Fu s i o n’s h i s to r i c a l
t i m e l i n e w a s o n e o f m y m o s t- u s e d to o l s . M y C A D m o d e l
to o k ove r 1 5 0 s te p s to m a ke, s o t h i s fe a t u re m a d e i t
e a s y f o r m e to ro l l b a c k i n t i m e to p rev i o u s p o i n t s i n m y
m o d e l a n d q u i c k l y m a ke c h a n g e s .
I a l s o u s e d Fu s i o n to m a ke q u i c k p r o d u c t i t e r a t i o n s a n d
to co m p a r e d i f f e r e n t f o rm o p t i o n s to o n e a n o t h e r– I
e n d e d u p m a k i n g 1 4 v a r i a t i o n s o f F o to b e f o re I l a n d e d
o n t h e f i n a l p ro d u c t . A
I w a s eve n a b l e to u s e m y Fu s i o n 3 6 0 m o d e l to c re a te a
p h y s i c a l 3 D p ri n t e d p r o t o t y p e, w h i c h g ave m e a m u c h
b e t te r s e n s e o f h o w t h e f o r m w o u l d fe e l i n re a l l i fe. B
[1, HDPE Safety Assessment, Dow], https://goo.gl/W5cBLM
[2, Paperboard MSDS, ACCO Brands], https://goo.gl/j7tLjK
[3, Soy Ink], http://soya.be
[4, Fiberglass laminate MSDS, Doosan], https://goo.gl/zPmEQN
[5, mPPE coated electrical wire], https://goo.gl/OHOViF