Design a commercially viable, domestic EV charger for a brand, with a focus on sustainability and manufacturability.
SMART
The Smart brand was selected as it was the first car manufacturer to release an all electric range. This EV charger would therefore sit nicely alongside that product range and fit in with the brand messaging.
Development
Inspiration
Sustainability
As the main focus of this project was sustainability, I created a report to highlight the key methods implemented throughout the design process.
Sustainability Methods
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Reduced surface area
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Reduced materials
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Design for disassembly
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Monochrome polymer
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Reduced Weight
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Materials Choice
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Transport packing
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Phosphorescent pigment
materials chosen were evaluated and compared to find the most sustainable option, based on energy consumption of production and moulding and carbon footprint.
Company Initiatives
To extend the life of the product and reduce the amount of material in landfill, there will be an option to have the unit updated and repaired. Free collection of the unit for disposal will be offered so parts can be reused.
Design
Sustainability methods were considered from the start of the design process such as with the shape of the product. The cube shape was chosen to limit surface area which will reduce the amount of material in the casing. The use of the phosphorescent material was added around the socket to illuminate the product in the dark rather than constantly having LEDs on, using energy.
Manufacture
Using a monochrome polymer for all the injection moulded parts means polymer can be purchased in bulk and used for multiple processes, reducing waste. The monochromatic polymer also means all parts of the casing can be recycled together. Disassembly is a key consideration to ensure the product can be fixed, and to recycle parts at its end of life. The
The report was designed in the style of the Smart brand using typography, colour scheme and document layout.
Key Innovations
Phosphorescent highlights
The yellow material around the socket and edge have phosphorescent pigments in which will absorb light in the day and emit at night. This means users will be easily guided to socket if they want to use the charger at night. This is more sustainable than having LEDs on for long periods of time.
LED ring
A ring of LED lights on the inner edge of the phosphorescent ring is used to indicate when the cable is connected and charging. This provides the user instant feedback on if the charger is working.
Ergonomic handles
The handles are designed with grooves that sit comfortably in the hand and the shape also reflects the bubble shape of the main body of the EV charger. The bubble shape is inspired the shape of the iconic Smart car. The handle also incorporates grips to help users get s secure hold of the handle.
SMART key
A Smart key can be used to lock the socket. This is to prevent unwanted other people from using the charger
Iris mechanism
The socket is opened and closed with an iris mechanism. This design was based off a camera shutter and tested using 3D printed test models. The spiral pattern creates interesting pattern even when the mechanism is closed.
Bubble shape
The asymmetric, boxy shape of the charger is inspired by the shape of the iconic Smart car. this is emphasized in the soft corners and slight curvature of the front face. A subtle hexagonal shape on the front surface also adds interest in the change of texture. This shape also reduces the volume of the product while still fitting all the internals. This was implemented as a sustainability method in the early stages of design as it will reduce the amount of material used
