ReFraming Material: Algae Based Biopolymer Eyewear 

by Jacob Gibson

Abstract

Material research offers insights for designers to create more considered and ethical material choices during production. Traditional petroleum-based plastics provide both durability and high usability in 3D printing; however, these plastics have longer life cycles than their intended use and cause irreversible damage to the environment. In contrast, the emergence of bio-based plastics, specifically, algae-based plastics for 3D printing, creates more ethical opportunities for designers to test material choices and production and reduce toxic waste.

Bio-based plastics are challenging the status quo in material production by providing an eco-friendly option. Whilst these developing materials have a positive premise, there are still doubts surrounding quality and usability. Through a practice-based research approach, this paper will discuss how a carefully designed methodology can have an influence on the practical design of products, specifically eyewear frames.

Material limitations should not be restrictive for designers, as challenges often occur during the design process when designing with emerging materials. A methodology can be created as a guide to how to design products and tailor specific testing methods to understand how material limitations will directly affect use. A series of eyewear frames, 3D printed in algae-based PLA, can be designed to demonstrate the designed capabilities of the material, challenge the norms of manufacturing, and show how a product-specific testing methodology can aid in the usability of material.

Design Intent

This project is exploring the potential of an algae-based polymer in a 3D printing filament, and how it can be used to create products; also, to offer an outline for other designers to use the material in the future to create their own products. This will provide designers with more options and a blueprint of how to test for and design with bioderived materials to reduce use of plastic waste through all stages of the design process.

The research-based aspects of this project concern the overuse of plastics by designers and how we can look at alternative, bioderived materials to enhance the design process. The material that is being studied is ALGA, algae-based PLA 3D printer filament, which is an optimised polymer infused with nuisance algae removed from waterways in the US and Asia. The material has several environmental benefits which include: aiding with nitrogen fixation of soil, being 100% biodegradable, environmentally sustainable, and non-toxic. The use of nuisance algae benefits aquatic life and water quality in the areas where it grows.  

3D printing serves as the ideal method to test a material like this, which is currently unable to be cast or injection molded. It also provides complete customisation of both testing and geometry, to understand how this material differs from traditional polymers. By utilising 3D printing, a testing methodology will afford a path to creating usable products from this material and could also provide a blueprint for similar bioderived materials.

A practical testing method will be used, connected to the intended product of eyewear frames to deduce a methodology that allows for material limitations to be designed around and ultimately create a functioning final product. The outcome of this will result not only in a methodology outlining how to test for specific products in the algae-based polymer, but also a documentation of all testing, results, and final designs. The eyewear frames will showcase the methodology, an example product that demonstrates the entire system of my methodology.  

Bio

I’m a passionate product designer who loves solving problems and reimagining products. I have a focus on user experience and exploring aesthetics and ergonomics, with an interest in the field of outdoor lifestyle and sporting products. I have an in-depth knowledge of Solidworks CAD and model making along with extensive experience with 3D printing. 

I’m excited to be able to utilise my conceptual design skills on a variety of projects and explore how I can use the skills I have gained through my education and past work experience. I love broadening my horizons by communicating and working with other designers and have a need for perfection in all my work, including both 3D CAD modelling and photorealistic rendering.  

I not only have a passion for design, but I thoroughly enjoy exploring future technologies with potential to impact the design world. I believe taking any project, and imagining how to have an impact on the broader design world, is the best way to future design and work within this world. Being proactive and self-motivated are key to moving forward in life and these are traits I believe will carry me through life and continue to serve me well. 

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