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S.F.J. Flipsen

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Repairable, Modular, and Open-source Hybrid Energy Storage System for Weak-Grid Regions of the Global South

Master thesis (2026) - S.W. Boermans, S.F.J. Flipsen, S.W. Franklin
In weak-grid regions of the Global South, millions of people rely on fossil-fueled backup generators (BUGS) to maintain their livelihoods, creating a shadow grid that accounts for significant local air pollution and health risks. Despite these environmental costs, BUGS persist as Dirty & Open systems: they are mechanically simple and highly repairable through vast informal economies of local mechanics. Conversely, modern clean Energy Storage Systems (ESS) are typically Clean & Closed, utilizing proprietary black-box architectures that prevent local servicing, leading to a mounting solar e-waste crisis when minor components fail.

This thesis presents Node Bawa, a repairable, modular, and open-source hybrid energy storage solution designed to provide a Clean & Open alternative. The concept leverages the imminent transition toward Light Electric Vehicles (LEVs) by utilizing standardized swappable batteries as the system's primary energy carrier. By bridging the gap between stationary home storage and mobile swapping ecosystems, Node Bawa serves as a central hub that supports both productive needs and personal mobility.

The research utilized a multi-disciplinary approach, including comparative disassembly mapping of industrial archetypes, factory visits in the manufacturing hub of Suzhou, China, and ethnographic field research in Bali, Indonesia. The resulting design features a split-module architecture consisting of an independent Inverter Module and a customizable Docking Module, connected by an ergonomic, tool-less coupling mechanism. Validation through iterative prototyping and thermal simulations confirmed the system’s ability to manage high-power loads safely while maintaining an intuitive experience for users without formal technical training. Ultimately, Node Bawa demonstrates that sustainable energy autonomy can be achieved by aligning modern hardware with the resilient, informal repair rituals of the Global South. ...
Industrial Design Engineering students regularly encounter difficulties applying mechanical principles during the design and prototyping process. Although theoretical knowledge is provided throughout the curriculum, many students struggle to translate intended movement into technically feasible mechanisms. This project investigates how a tangible learning tool can support students in developing a more intuitive understanding of mechanical principles through physical interaction and experimentation.
A Research-through-Design approach was adopted, combining literature research, observations made during three years as a teaching assistant, educator interviews, iterative prototyping, and user evaluations. Five exploratory prototypes were developed to investigate different educational approaches, interaction methods, and construction systems. The resulting design, the Mechanical Garden, is a magnetic modular learning platform that enables students to rapidly build, modify, and experiment with mechanisms such as gears, four-bar linkages, and rack-and-pinion systems while immediately observing the effects of their design decisions. Educational exercises and supporting materials were developed to encourage active experimentation and conceptual learning.
The Mechanical Garden was evaluated with seven participants using pre-tests, post-tests, questionnaires, observations, and interviews. Average test scores increased from 54% to 91%, while participants reported that the system made mechanical concepts easier to understand, encouraged experimentation, and helped connect theoretical knowledge to practical applications.
The findings demonstrate that combining tangible interaction with guided learning activities can effectively support the understanding of abstract mechanical principles. Rather than replacing existing teaching methods, the Mechanical Garden is intended to complement engineering education by providing an accessible, engaging, and hands-on learning experience.
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Redesigning Couches for Disassembly, Reupholstery and Foam Replacement

Couches are frequently discarded while their frames, suspension systems and other structural components still retain functional and economic value. Refurbishment could extend product lifetimes, but current couch constructions make the main wear components, particularly foam and upholstery, difficult and labour intensive to access and replace. This graduation project investigated which product design interventions could enable furniture producers to repair and refurbish their own couches more efficiently.

The research was conducted in collaboration with The Bin and Dutch Quality Group. The analysis identified glued foam and difficult to remove upholstery as the main product level barriers to refurbishment.

Two design principles were developed. The first divides the seat foam into interlocking compartments, allowing worn areas to be replaced locally. The second uses a pullcord to tension and release the upholstery without destructive fastening. These principles were combined in a demonstrator cushion with replaceable foam blocks, a flexible felt inlay and a reversible fabric cover.

The comparison indicates that replacing one third of the foam could reduce the estimated refurbishment time from 48 to 36 minutes, lower costs by approximately 45 to 50 percent and require 67 percent less new foam than full cushion replacement. An indicative climate impact comparison estimates that approximately 447 kg CO₂ equivalent could be avoided for two couch modules over three life cycles. However, the demonstrator increases initial production costs and has not yet been validated for long term comfort, durability or industrial production.

The project concludes that the developed concepts are most relevant to high quality couches with sufficient residual value to justify refurbishment. More broadly, it demonstrates that refurbishment can be supported by treating foam and upholstery as accessible wear components that can be inspected, removed and replaced without damaging the remaining product.
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A Circular Strategy for Ski Boots

Master thesis (2026) - M. Mairhofer, C.A. Bakker, S.F.J. Flipsen, Helmut Holzer
The winter sports industry depends on stable climatic conditions, yet its equipment, infrastructure, and travel systems contribute significantly to environmental degradation. Ski boots exemplify this contradiction: although engineered for durability, they typically pass through only a single ownership cycle, destroying substantial embodied value. This is reinforced by combining components with different lifespans into a single product, where the faster-degrading parts determine when the boot is replaced.

This thesis explores how a circular business model can enable economically viable value retention for ski boots, and which product adaptations are required to support such a system. The research combines literature review, product disassembly, life cycle assessment, expert interviews, and quantitative user surveys to identify the key barriers to circularity.

The findings reveal that 84% of a ski boot’s environmental impact is generated during production, while its most carbon-intensive component, the shell (hard outer boot), remains structurally functional well beyond its typical use phase. Yet boots are frequently replaced prematurely due to liner (soft inner boot) degradation, comfort loss, and perceived obsolescence. Together, these dynamics reveal five systemic tensions: mismatched component lifespans, aesthetic value loss, lack of lifecycle control, limited return infrastructure, and ownership structures that discourage reuse. Rather than addressing these in isolation, they form the foundation for an integrated product–service system.

The thesis proposes a circular model in which the durable shell is retained and redistributed across multiple use cycles, while the liner remains a personal component. Once a shell no longer meets the demands of its initial use, it does not lose its value; instead, it is reassigned to a context where its performance still meets user needs. Value is captured through controlled refurbishment, performance-based grading, and structured return mechanisms. Deliberate product adaptations are introduced to make the system viable, including reversible connections that enable the replacement of high-wear components and design interventions addressing aesthetic degradation.

The thesis shows that value retention is not limited by technical feasibility, but by system design, ownership structures, and user perception. Circular value retention emerges not from isolated product improvements, but from the integration of product, business model, and system design. Design, therefore, plays a key role in reshaping how value is created, maintained, and recaptured over time.
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Designing Force-Sensing Tools for Disassembly

Master thesis (2026) - F.J.T. de Groot, Bas Flipsen, Adrie Kooijman, Doris Aschenbrenner
Lithium-ion batteries are increasingly built into disposable products like vapes. When discarded, they are hard to remove. Batteries left inside cause fires in waste processing, and their lithium is lost. Manual extraction does not work at scale. The varying conditions of waste products have been difficult for programmed robotic approaches to deal with. However, imitation learning, in which a robot learns from human demonstrations, is starting to handle this kind of variation. Hand tools used in manual disassembly have received less attention in this field of robotics. This project approaches the problem through the tool, focusing on prying with a spudger (a thin, flat opening tool). Three questions guide the project: What must the tool sense? How should that sensing be represented? And what does it take for a robot to learn prying from a human?

These questions were investigated through a Research through Design approach. Expert interviews suggested that disassembly knowledge lives in people’s hands and is partly lost when transferred to a robot. In a disassembly mapping experiment, a multimodal AI model analyzed recordings of product teardowns. The spudger was among the most used tools, and from video alone, the model struggled to recognize force and hidden friction fits. Teleoperation tests with the SO-ARM 101 (the robot platform used in this project) showed that a contact-rich task like prying is difficult, as the feedback loop between hand, tool, and force is broken.

These insights led to the design of a force-sensing spudger attached to a robot arm. Force data was integrated into the robot’s policy (Action Chunking with Transformers) as three channels: current value, recent change, and recent peak. Two policies were trained on the same 50 demonstrations, with and without force. With force, the robot fully extracted the battery in 30 of 31 trials; with no force, it only succeeded in 13 of 31 trials.

Based on these findings, the Robotic Spudger concept is a proposal for how a tool could capture tacit knowledge and pass it on to a robot. A human teaches with the tool, the robot performs with it, and the human takes over with the same tool to correct mistakes.

The insights discovered throughout this project were translated into two sets of design guidelines: one for designing products that are to be disassembled by robots, and one for designing shared tools that a human and a robot can both use. The work here only covers one disassembly step on a 3D-printed dummy battery in a fixed position, demonstrated by one person. Within that scope, it shows that a tool can also be the interface through which practical knowledge is captured and partly transferred to a robot.
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A practical toolkit on how to prevent aesthetic obsolescence

Master thesis (2025) - J.N.A. Polderman, R. Mugge, S.F.J. Flipsen
Cosmetic obsolescence, characterised by visible wear that diminishes a product’s perceived value, contributes to premature replacement. While material ageing can add to a product’s identity, practical guidance for designing products that age gracefully is lacking. This project focuses on how designers can use ageing and changing materials to stimulate product retention.

A research-through-design approach was employed. The literature on replacement behaviour and perceptions of material ageing was combined with user research and an observational study of worn headphones to form key takeaways. These takeaways guided ideation and prototyping for headphones that age gracefully. Design directions were generalised into early strategy principles and refined through an expert session, a creative session, and coach meetings. The scope of this project is limited to cosmetic obsolescence; functional strategies, such as modularity and repair, are excluded.

The resulting Design Toolkit for Gracefully Ageing Products supports designers in addressing cosmetic obsolescence. It presents four strategies: Prevent (protect against wear), Heal (enable maintenance), Hide (camouflage wear), and Show (highlight wear as a value).

The final concept demonstrates the toolkit and integrates the four strategies into a coherent design called Scratch Art. The concept focuses on Show: A black coating wears away to reveal coloured scratches, redefining the perception of wear in plastic. It prevents dirt buildup at the cup-headband connection through a connection design that reduces dirt accumulation. It heals through washable cushions that restore cleanliness. Lastly, it hides dirt with a patterned mesh that visually masks stains. ...

Design for the reusability of endovascular inflators

Inflators play a crucial role in interventional radiology and cardiology to restore blood flow to obstructed veins. Given the high-risk nature of these procedures, inflators must be sterile. Consequently, they are designed for only single-use. This practice results in the annual incineration of around 100.000 inflators annually in the Netherlands, contributing to approximately 62500 kg of CO₂-eq emissions.
Our research, employing literature review, HotSpot and Disassembly maps, interviews and observations identified key barriers to reuse of the current inflators. These devices are designed for single-use, applying materials that cannot withstand decontamination and lacking the ability to be disassembled. In addition, parts are fixed together to reduce the chances of failure during the procedure.
This master’s thesis proposes a circular model for endovascular inflators, focusing on the reuse of valuable components within healthcare institutions while disposing of the rest. POMPA. POMPA is a circular redesign of the inflators. It aims to make inflators easy and safe to use, disassemble, decontaminate, reassemble and reuse. POMPA adopts materials suitable for decontamination and redesigns the architecture of inflators to achieve complete dis- or reassembly of the product in less than a minute without compromising its functions and performance.
The new system and product-level interventions enable the decontamination and reuse of key components for about 1000 patient procedures. POMPA has a lower environmental and economic impact than current single-use inflators after just nine uses.
In conclusion, POMPA offers a sustainable, convenient, and safe alternative to single-use inflators. This conceptual solution has many features that can be further explored and improved, but for now, it is intended to be a first step towards more circular inflators and to inspire similar innovation change in other medical devices. ...

A repairable headphone, rethought through its user guide

Master thesis (2025) - I. Bosch, S.F.J. Flipsen, C.A. Bakker, K.S. Sekijima
This graduation project, conducted in collaboration with Sony Corporation, explores how over-ear wireless headphones can be redesigned to better align with the principles of the circular economy. The current design of consumer electronics, including headphones, largely follows a linear model. This results in short product lifespans, limited repair options and significant challenges for recycling. This project takes a different approach, fundamentally rethinking how users interact with and care for their products.

While most consumer electronics are designed as closed systems, this project investigates how design can shift the perception of headphones from being a ‘black box’ to an understandable and approachable object.

The analysis of five existing headphone models identified key barriers to circular user behaviour, including complex design, inaccessible critical components, difficult disassembly processes due to interdependencies, the extensive use of adhesives, lack of intuitiveness and the product being perceived as a ‘black box’.

In response, a new concept was developed that centres on re-teaching the practice of product care through clarity. Central to the design is an illustrated book featuring transparent elements that serves as a walk-through of the headphones. This allows users to familiarise themselves with the headphones’ internal architecture, functions and maintenance possibilities without risking damage.

According to the principles of this book, the Sony WH-1000XM5 has been redesigned to follow the same modular, layered structure. Transparent structural parts and colour coding by function reinforce the visual connection between the two. The book and the headphones work together as a single system, with each one strengthening the other.

The final concept demonstrates how design can encourage users to take care of their products by teaching them how to maintain, repair and handle them responsibly throughout their lifecycle.

This project introduces a new approach to circular design and product design in general, placing the supply of information at the centre and adapting and optimising the design of the product to support it. ...
Master thesis (2025) - J. Mortier, A.R. Balkenende, S.F.J. Flipsen, Bianca van der Zande
This report aimed to take a look at the relation between repair and recycling, while considering the user aspects and application. This has been done by analysing two waterproof linear shaped luminaires on their ease of installation, repairability, and recyclability by doing interviews with installers and recyclers, using the Disassembly and Recyclabity map, and conducting a shredding experiment.

Insights from analyses which were interesting in the scope of this project included: repair of the luminaire on site is hardly done due to high labour costs and low failure rates of the components and installers are willing to disassemble at the end of life to improve liberation in recycling. Shredding experiments showed complications in the recyclability of the seal, metal folding around other parts and materials not being recycled in the WEEE line, like PC.

As a result of the analyses, redesign directions have been identified and ideas have been generated. From those ideas, one concept has been chosen with the help of experts to maximise the benefits in the installation, repairability and recyclability, as well as the feasibility and costs.

In the redesign focus lay on making the parts in need of maintenance (the battery and driver) and the electrical connector quickly and easily accessible for the installer on site, while improving the recyclability of the luminaire and considering the application requirements of waterproofness. The redesign shows both the driver and batteries are accessible on site in 10 seconds with a complete battery replacement taking 31 seconds in total (compared to 148 in the old design). Next to that, uni-material assemblies have been strived for to increase the recyclability.

The thesis finalises with an advice to designers on how to design for recycling, repair, and for all domains simultaneously and shows the relevance of keeping in touch with the intended user throughout the project. ...
Since 2011, large amounts of seaweed, sargassum, have increasingly impacted the Caribbean, with 2025 having another record influx. The resulting sargassum inundation events cause severe ecological degradation, public health concerns and economic losses for coastal communities that rely heavily on tourism, like the area of Quintana Roo in Mexico.
The existing nearshore barriers often fail to intercept most of the sargassum due to poor coordination, unsuitable anchoring, poor design or excessive sargassum accumulation in “sacrificial zones.” If sargassum is allowed to stay still for more than 36 hours, it decomposes, releasing toxic gases, heavy metals and arsenic. The sacrificial zones are a problem area that all current onshore solutions share. To address this issue, this study features the design of a floating nearshore system that transforms these sacrificial zones into “opportunity zones”. It enables efficient interception and guidance, concentration, and extraction of sargassum before it reaches the shore. To attain the goal of the design, a multidisciplinary approach was applied; combining environmental and stakeholder analyses,the system design of a barrier with a collection point, and hydrodynamic simulations in Delft3D to optimize barrier orientation and performance. Different design concepts were developed and evaluated based on technical, operational, and environmental criteria. The resulting concept of the system features a modular floating barrier that guides sargassum towards a designated collection point, the opportunity zone, for extraction. This barrier is supported
by a buoyancy-stable floater, flexible mesh skirt, innovative connections and mooring system. The hydrodynamic analysis confirmed that the orientation of the barrier compared to the barrier significantly affects the flow efficiency of sargassum along the barrier. Through the hydrodynamic analysis, an optimal barrier angle was found to maximize redirection and minimize the length of the barrier. The collection point proposes a solution to collect clean sargassum, whilst minimizing the impact on the environment. This study shows that integrating civil engineering, design thinking, and local knowledge can yield a sustainable near-shore solution. It has to be noted that there are aspects of the design that need further consideration and detailing. This study forms a foundation for scalable sargassum
management. ...
Master thesis (2024) - B. Dekkers, S.N. Paus-Buzink, S.F.J. Flipsen
Neurodegenerative diseases like Parkinson’s and Alzheimer’s have a huge impact on patients, their close ones and society as a whole. The negative consequences of these diseases are ever increasing due to our ageing society and growing shortage of healthcare personnel. Worldwide research efforts have thus far been unable to find effective treatment options.

Brain deterioration in neurodegenerative diseases sets in 15 to 20 years before clinical symptoms become noticeable. This means that even if better treatment options become available, much irreversible damage has been inflicted before we know to administer the treatment.

Early deterioration of smelling ability has been shown to provide a good risk indicator for future disease development. This thesis dives into the sense of smell as a means of recognizing neurodegenerative diseases preclinically.

An olfactory evaluation tool, called Knowse, was developed. This concept product was designed to make the well-known ODOFIN Sniffin’ Sticks test suitable for the context of case-finding for neurodegenerative diseases. Knowse transforms the Sniffin’ Sticks into an automatic self-test that people may use at a brain health clinic or optician. The product provides people with a relative trendline of their smelling ability, from which conclusions can be drawn over time.

This thesis report features a deep-dive into the neurodegenerative diseases Alzheimer’s and Parkinson’s, their impact and their current procedures. Possible future test locations, ethics of diagnostics and the current olfactory test market are explored through interviews and literature research.

Several design methods, prototypes and design iterations are described as they lead towards the final concept product of this thesis, Knowse. Design focused much on the technical, usability and error-proofing aspects of the concept product. ...
Master thesis (2024) - S.T.B. Wiltingh, S.F.J. Flipsen, F.P. Wilbers, Parshva Mehta
Plastic pollution in Dutch waterways is a growing environmental challenge, contributing to ecological damage, public health risks, and increased operational costs for maintenance and cleanup. This report focuses on the redesign of Noria’s floating litter tracker, the TrashTracer, to address key limitations in the original design, including water ingress, insufficient durability, and high production costs. By employing a user-centered design process, the project incorporated modularity, improved waterproofing, better signal reliability, easier recovery, lower chances of losing the tracker and extended battery life, resulting in a more effective research tool.
Through iterative prototyping, stakeholder feedback, and technical analysis, the redesigned tracker enhances operational efficiency and creates added value. The project also ensures the tracker aligns with Noria’s mission to research and mitigate plastic pollution, contributing to broader efforts to improve the quality of aquatic ecosystems in the Netherlands. The report concludes with an evaluation of the project’s results and recommendations for implementation. ...
Master thesis (2023) - J.O.I. Bahlmann, S.F.J. Flipsen, C.A. Bakker
This project aims to develop an easy-to-use method to (re)design products for ease of disassembly and subsequently for circular strategies, such as repair, refurbish, remanufacture, etc. Improving repairability is one of the first steps in decreasing the environmental impact of products by prolonging their technical lifespan. This thesis focuses on two separate tools that have the potential to be integrated: the Hotspot Mapping tool and the Disassembly Map. Both tools assess a product by disassembling it into its core parts and recording the properties of the parts and the disassembly steps (Fazio & et al., 2021; Flipsen et al., 2020).
The Hotspot Mapping tool highlights parts and disassembly activities that are important due to their failure rate, functionality, disassembly effort, and environmental and economic impact. On the other hand, the Disassembly Map uses these highlighted features to create a visual representation of the product architecture. Since the inputs for both tools are similar, it raises the question of whether it is possible to link them together.
The tools are analysed by literature review and usability questionnaires, resulting in a usability score of the original tool and strengths and weaknesses in terms of features and usability. Through an iterative approach, a new tool is developed, that uses a node/edge lists data structure to describe the product architecture of a product. This data-structure allows for the automatic generation of a dynamic Disassembly Map (Figure 1) in the visualisation software program yEd Graph Editor. The dynamic Disassembly Map allows designers to select which properties to display and which to hide, enabling focused attention and a better overview.
Through user testing the new method has been proven to offer increased usability, requiring less time to fill in, and an overall preference by all usability test participants over the original Hotspot Mapping and Disassembly Map tools. ...
Master thesis (2023) - M.O. Rademakers, S.F.J. Flipsen, S.S. Mulder
Action is working on sustainability in social compliance, materials, packaging and circularity but they still have a long way to go in becoming circular. The European Union is taking steps towards a circular economy with the New Circular Economy Action plan, The Green Deal and the Right to Repair. Countries and companies are taking measures where legislation on the European level is taking too long. Action’s geographic expansion is ending and needs to look for new opportunities. This thesis will focus on helping Action to take their responsibility in the cycle of products to make them more circular. This will help Action to stay resilient with upcoming European legislation, by being in compliance with present and foreseeable circularity legislation .This has led to the following research question: How to help Action in becoming Circular to stay resilient with present and foreseeable legislation?

Using the double diamond method the most vulnerable product group and corresponding circularity strategy was selected. The first diamond was used to select a product group to focus on and what strategy should be applied. The focus should be on repairability as it is a starting point for other CE strategies. Electrical and electronic equipment is the most vulnerable product group to legislation and is forcing Action to take responsibility after Energy Related Products (ErP) have been sold. ErP have the biggest potential to reduce CO2 emissions. Therefore, Action should focus on selling repairable ErP as a step towards circularity. The buyer has a lot of power in making decisions but is lacking the knowledge of making decisions in terms of circularity. The problem that needs to be solved is that the buyer is making decisions on purchasing ErP products while lacking repairability knowledge. This is developed in the last diamond of the double diamond method.

To help Action stay resilient with present and foreseeable legislation a repairability index is made which Action can use to quantify the repairability of products. This repairability index is specific for every ErP group and is made by Action. This is made possible through an index guide that helps select priority parts and reference values for the repairability index of every specific ErP group. Suppliers can fill in the repairability index using the supplier guide. A repairability index feedback system is used by the buyers to keep track of the repairability of the products they buy. The repairability index is accompanied by a future vision which aims that Action has build a vibrant ecosystem through innovative partnerships and collaborations in 2035, where Action works together with its manufacturers, repairers and customers to create a circular future where customers are empowered to repair Action's durable products more easily. Getting here is explained through a roadmap with three horizons. ...

A Novel Forward-Facing Seating Concept

The project as described in this report led to the development of a seating system for a compact campervan based on the Volkswagen ID Buzz, an electric vehicle recently released by Volkswagen. It erupted from a challenge occurring at Ventje, a company manufacturing compact campervans in Culemborg. The introduction of a the new campervan, based on the ID Buzz, brought with it many challenges, one being its’ higher price and smaller formfactor. These two combined brought the concern whether this vehicle kept the same desirability as the original model, based on the VW Transporter. The opportunity that was explored for this project was whether the ID Buzz based Ventje could offer a more multifunctional character in order to utilize it’s potential as a decent family car. The analysis for the project was split up in two sections, product analysis and user analysis, which concluded that Ventje offers better camping functionality and aesthetics as opposed to the competition, who offered more comfortable back seats for use during driving and so-called versatility, meaning the van can adapt to other use cases by adding or removing components. Based on the results from the product and user analysis, the choice was made to develop a solution to add two comfortable back seats that can be integrated in the new campervan based on the ID Buzz with the aim to make it directly implementable in the interior that was designed thus far for the ID Buzz campervan, called eVentje. This led to the development of the seating system, which arguably improves the Ventje interior concept overall and improves multifunctionality of the van. The seating concept has been evaluated in a study using a 1:5 scale model, which showed that functionality of the system is not compromised, however components of the system should be designed for lightweight and ergonomically as this was still a concern among respondents. ...
This graduation project delves into the use of Additive Manufacturing (AM) to produce spare parts through a case study of vacuum cleaners. Waste from Electrical and Electronic Equipment (WEEE), including products like vacuum cleaners, challenges the European Union’s (EU) sustainability goals. In 2020 alone, the EU collected an estimated 12.4 million tonnes, representing 10.5 kilograms per person. To address this issue, the “Right to Repair” was adopted. This initiative aims to promote repair as a strategy to slow down WEEE by mandating companies offer 10 years of post-warranty spare parts availability and 15 days of lead time. This mandate challenges companies’ responsiveness due to the extended period of support and limited lead time. Am provides an opportunity to fulfil these requirements while also offering additional benefits such as the digitalisation of the supply chain and reducing the environmental impact of the company’s operations.
The main research goal of the project is the development of a framework for evaluating the suitability of components within a product to be AM printed as spare parts. The framework is established through a literature review across three primary research areas: Priority components (identifying key components for repair activities), Printability (assessing component suitability for AM printing) and Spare Part Suitability (evaluating components’ suitability for supply chain considerations). The proposed framework, encompassing three primary steps, narrows down the components from a complex product to focus on those that present greater AM eligibility. This, in turn, guides the company’s effort in designing, testing and making these eligible parts commercially available.
Step 1. Cut-off criterion: Aims to exclude components defined as not suitable for AM printing, such as standardized elements and electronics.
Step 2. Eligibility Evaluation: Assess components eligibility for AM spare parts printing within the research areas.
Step 3. Component Selection: A top-down approach is employed. It begins with the selection of repair priority components, from his group those deemed AM printable are identified, and finally, components aligned with supply chain suitability are selected.
Takeaways from the conducted research also involve the insights gathered from the conducted framework validation, which involved two Philips vacuum cleaners and the use of Selective Laser Sintering (SLS) for the printing of spare parts. Lastly, this thesis establishes a foundation for the exploration of AM potential in the realm of spare parts manufacturing and future product design.
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Concept design of an electric toothbrush ready for the circular economy

Master thesis (2022) - M. Drummen, Ruud van Heur, Bas Flipsen
Electric toothbrushes are the most effective method for maintaining oral hygiene, but also the method with the greatest environmental impact. Most of the impact of electric toothbrushes comes from transport, materials and parts. This means that by extending the product life and enabling local loops, the environmental impact of electric toothbrushes can be reduced. The circular economy encompasses multiple strategies that can be leveraged to achieve this.

So far, there has been little research into designing small waterproof personal care appliances for the circular economy. In this thesis, the challenges and opportunities for transitioning electric toothbrushes to the circular economy are uncovered and a design solution to these challenges and opportunities is proposed. The primary research question for this thesis is:

How can an electric toothbrush be designed suitable for the circular economy?

The first two phases of this thesis were dedicated to uncovering the challenges and opportunities for transitioning electric toothbrushes to the circular economy. In the first phase, research into the state of the circular economy of current electric toothbrushes was performed in which the academic, manufacturer and user perspectives were researched. This led to three key insights for the circular design of an electric toothbrush. In the second phase, an analysis was performed of the implementation of circular design strategies in a representative set of current electric toothbrushes. This led to four key insights for the circular design of an electric toothbrush.

In the third phase of the thesis, the key insights were translated to design challenges and a design solution to tackle these design challenges was conceived. This resulted in the Everbrush electric toothbrush concept.

The battery has been made user replaceable to tackle the primary reason for reaching the end of life, reduced battery performance. An aluminium main body was introduced that aims to increase product attachment by ageing with dignity, which should also increase repair considerations. Another aim of the aluminium main body is to reduce hygiene concerns when purchasing refurbished. The ease of disassembly has been improved significantly which can open up additional opportunities for product life extensions. The amount of elastomers has been reduced by introducing a rotating magnetic power switch, eliminating the need for a power switch seal and increasing high-value recycling performance. Lastly, permanent connections were avoided throughout the design, also increasing high-value recycling performance.
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Connecting potential to create value in a circular economy

In this graduation project the design process: the Potential to Value Circle, for designing from a waste stream is presented. The Potential to Value Circle creates a structured way of working in which the potential of a waste stream is translated to value. Value is generated by combining the perspectives of material, stakeholders and context around a waste stream into a concept direction. Through this process, The Bin guides their clients to take the next steps in becoming part of a circular economy.

This project was done in collaboration with The Bin. The Bin is a startup in the circular economy. They help their clients to become part of a circular economy by creating circular concepts out of their waste streams and setting up a circular system around these concepts. These waste streams can be defined as products at their end-of-life or by-products from a production line.

Currently, the Bin bases its process on the circular frameworks the Value Hill (Achterberg et al., 2016), R9-list (Potting et al., 2017) and the Butterfly diagram (EllenMacArthur Foundation, 2019). These frameworks give the bin a high-level overview of circular value creation. However, they want to have a more step by step process that helps to turn waste streams into circular concepts. This was the essence of their request for this graduation project and resulted in the Potential to Value Circle.

The Potential to Value Circle approaches a waste stream from different perspectives, resulting in opportunities that get turned into a concept direction that uses the waste stream to move towards a circular economy. The Potential to Value Circle is built up in three phases, 1) Analysis, 2) Combining, and 3) Circular design goal. The first phase presents how an understanding of the elements around a waste stream can be created, by analysing material, stakeholders and context. Based on this, potentials are formulated. In phases 2 and 3, the potentials of phase 1 are combined, which allows translating the potentials of the waste stream into opportunities. With these opportunities, a concept direction is formulated that creates value. Three ways of applying the Potential to Value Circle are presented, on which the Workshop is elaborated further. The workshop shows how to work in three hours with the Potential to Value Circle to a circular design goal with the client.
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To design a personalized energy efficient heating solution for the in-door environment

Master thesis (2022) - M.T. Ulusoy, H. Kuipers, S.F.J. Flipsen
With the already happening governmental regulations(The Netherlands), an increase in consumer price of natural gas is noticeable. With COVID-19 and now the war in Ukraine energy resources are becoming increasingly expensive. 90 percent Dutch houses are heated with gas. Based on the energy consultant, gas supplies an average to 9769 kWh of energy per m3. Each house use up to 1500 m3 per year. 14654 kWh for a year on an average is needed for one household. A heat pump (HP) needs about 6513 kWh average per year depending on type house, size and season. From society we are going through a shift from gas to electricity. For a house this can be done with replacing a gas based boiler with for instance a heat pump. But it doesn’t necessarily provide people the same scale of thermal comfort. Shouldn’t we rethink the way we feel comfortable in our homes? Design opportunities that contributes to Bosch’s future vision and mission are explored. The problem at the heart of this project is defined as: To what extent can a product increase the personal thermal comfort of the user and be more energy efficient? And can therefore a personal product provide the necessary heat if the central heating temperature settings is set to 18°C? User-centered design and thermal comfort are the key methodology and research supporting this project. Both were used for exploring the relationship between users’ behaviour (personal heaters) and the influencing factors, thereby providing valuable insights for all design directions. This project is finalized with a product concept, “Ori”, a flexible Far Infrared (FIR) heater that has multi product configurations and use-cases. It applies various design criteria based on the inputs of thermal comfort research, user interviews, heating technology research, aiming and product flexibility configurations to create a personal experience for users. If the challenges are addressed, Ori could be a valuable product for Bosch’s consumer products portfolio and offer the user financial benefit and a decrease in yearly electrical energy consumption. Ori will use up to 229 kWh per year which is nearly 10 times less compared to a conventional personal heater (2148 kWh). The performance would be measurable through a simulation of a working HP, a room, a user, Ori and a Predicted Mean Vote (PMV) measurement device that address thermal comfort (ISO 7730). In addition to this concept, this project has addressed possible opportunities and requirements in the field of FIR heating, which could be used as an input for other relevant product developments within Bosch’s (thermal) comfort and well-being department. ...
To improve efficiency, dairy farmers monitor the inputs and outputs of their cows based on data collected by sensors. Currently the main sources for this data are the given food and information about the milk (composition and volume). This data helps the farmer make better decisions regarding animal welfare and feeding practices. However, one of the outputs of the cow is currently not monitored, namely the manure.

A system that monitors herd manure data in a barn using sensor technology was proposed. It should give the farmer interpreted feedback enabling him to have more control over farm efficiency both financially and ecologically.
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