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Sustainable manufacturing for repair and reduction of waste

A Double-Diamond Approach towards Sustainable Manufacturing for Repair and Reduction of Waste 

Wire Arc Additive Manufacturing (WAAM) uses materials that are available as welding wire that can be used to manufacture parts. Although this opens huge manufacturing capabilities and applications, awareness about WAAM is still growing. There is also insufficient evidence to back the use of WAAM that claims to have a minimal material loss and uses less energy as compared to conventional manufacturing methods. Kingsbury company wishes to better understand how design thinking can be used as an enabler for new products and services associated with WAAM. 

This project aims to utilise the Double-Diamond Design Method to adopt more sustainable production practices for high value components using WAAM. The vision is to embed the use of the Double-Diamond Design method within a manufacturing company, Kingsbury, with a view of adopting and promoting sustainable production methods that will lead to net zero waste of materials.

This design method will enable a divergence-convergence approach to explore barriers concerning the adoption of sustainability, followed by taking focused action through two case studies and culminating with a proposed circular business model. Brunel University London (BUL) will partner with Kingsbury to examine whether WAAM that has been recently made available is a more sustainable as compared to conventional manufacturing methods.

This project is an excellent fit with Kingsbury's business strategy to better understand the value of design through the Double-Diamond method as a vehicle to discover how net-zero can be embedded into the company through innovation and sustainability training workshops, referring to existing sustainability tools (lifecycle assessment, eco-auditing, etc.) to quantify the use of WAAM using theoretical calculations as being sustainable, outlining how the WAAM process can reduce material waste and extend the lifetime of existing components. In the longer term, the value of design knowledge brought by BUL, will be more deeply embedded into the company, thereby extending the concept of design thinking to other products and services within Kingsbury and its suppliers.


Meet the Principal Investigator(s) for the project

Dr Eujin Pei
Dr Eujin Pei - Academic Background Eujin is Associate Dean of the College of Engineering, Design and Physical Sciences (ADQA-CEDPS), working closely with colleagues to actively monitor and implement quality and standards in relation to academic programmes across the college and providing strategic leadership and management to the faculty. He is the Director for the BSc Product Design Engineering Programme, a Chartered Engineer (CEng), Chartered Environmentalist (CENv) and Chartered Technological Product Designer (CTPD). As a Product Design Engineer during the early days of his career, he developed solutions for companies including Motorola, Inc., LM Ericsson, Sennheiser GmbH & Co. KG, and Rentokil Initial. His research focuses on Additive Manufacturing and 4D Printing. He is the Chairperson for the UK National Standards Committee for Additive Manufacturing - British Standards Institute AMT/8; and UK Head of Delegate for ISO/TC261. He is the Convenor of the International Organisation for Standardisation ISO/TC261/WG4 that develops global Standards for Additive Manufacturing Data and Design; and Convenor of ISO/TC261/JG67 for Functionally Graded Additive Manufacturing. Eujin is a Full Member of the EPSRC Peer Review College as the national agency that assesses proposals for funding Research in Engineering and Physical Sciences. He is a Member of the EPSRC Engineering Prioritisation Panel, and Member of the EPSRC Engineering Fellowship Panel. In 2018, he became a Member of the EPSRC Early Career Forum in Manufacturing Research that involves participating in EPSRC strategic advisory activities.  Eujin is the Editor-in-Chief for the Progress in Additive Manufacturing Journal (SpringerNature), Associate Editor for Journal of Intelligent Manufacturing (Springer) and Associate Editor for Assembly Automation Journal (Emerald). He is an Editorial Board Member for Rapid Prototyping Journal (Emerald), and Member of the Editorial Board for International Journal of Rapid Manufacturing (Inderscience). He is a reviewer for Cogent Engineering (Taylor & Francis); Journal of Manufacturing Processes (Elsevier); Manufacturing Letters Journal (Elsevier); Optics and Lasers in Engineering (Elsevier); Materials & Design (Elsevier); Nature Communications (Nature Publishing Group); International Journal of Manufacturing Technology and Management (Inderscience); Advances in Mechanical Engineering Journal (Sage Publishers); Journal of Engineering Manufacture (Sage Publishers); Journal of Mechanical Design (American Society of Mechanical Engineers, ASME); Recent Patents on Engineering (Bentham Publishers) and the International Journal of Design (Open Access). He is also reviews for Palgrave Books (Macmillan Publishers Ltd.), Laurence King Publishing Ltd. and SpringerNature AG. Research Eujin leads the Additive Manufacturing & 4D Printing Research Group with his interest focusing on Additive Manufacturing and Smart Materials. He is also the Co-Director for the Brunel Centre for Digital Manufacturing. He gained hands-on experience as a Research Fellow at Loughborough University, Brunel University London and at the University of Southampton. He was a Visiting Scientist at Vaal University of Technology and at Central University of Technology in South Africa. His active involvement in professional Memberships enable him to be a step ahead in policies and emerging technologies. He is an active Member of the British Standards Institution TDW4/8 that develops Standards such as BS 8887 for Design for MADE; and BS 8888 for Technical Product Specification. He is a Member of ISO/JTC1/WG12 which develops standardization work for 3D Scanning and 3D Printing within the scope of Information Communication Technology. Eujin also regularly participates in ISO/TC 261/AHG 05; ISO/TC 261/AHG 06; ISO/TC 261/JG 74; and is a Member of ISO/TC 261/CAG Chairman's Advisory Group, and ISO/TC 261/JAG ISO/TC 261 - ASTM F42 Steering group on JG activities. As Convenor for ISO/TC 261/WG4, he oversees the work of  ISO/TC 261 - ASTM F42 joint groups including ISO/TC 261/JG 54 Joint ISO/TC 261-ASTM F42 Group for Fundamentals of Design; ISO/TC 261/JG 57 Joint ISO/TC 261-ASTM F42 Group for Specific Design Guidelines on Powder Bed Fusion; ISO/TC 261/JG 64 Joint ISO/TC 261-ASTM F42 Group for Solid Modelling Support; ISO/TC 261/JG 70 Joint ISO/TC 261-ASTM F42 Group for Optimized Medical Image Data; and ISO/TC 261/JG 73 for Joint ISO/TC 261-ASTM F42 Group for Digital Product Definition and Data Management. Eujin is a Fellow of the Institution of Engineering Designers (FIED). He is a member of the Engineering Council Registration Standards Committee (RSC) that publishes procedures, routes and requirements for the UK Standard for Professional Engineering Competence (UK-SPEC) for registration as Engineering Technician (EngTech), Incorporated Engineer (IEng) or Chartered Engineer (CEng) and Fellow of the Higher Education Academy (FHEA). He is a Member of the Design Research Society (DRS) and Co-Founder of the Inclusive Design Special Interest Group. At Brunel University London, Eujin is a Committee Member for the Innovation Hub which spearheads new initiatives for student entrepreneurs. He has a track record of generating new knowledge and finding solutions for significant impact in the industry. He is active in Knowledge Transfer Partnerships (KTP) and worked with BAE Systems Applied Intelligence Ltd. on several industry projects. In 2016, he was nominated for the BAE Systems Chairman’s Award that acknowledged the efforts and achievements of company partners who delivered performance and furthered the company’s values. Through Knowledge Transfer Partnerships, he has collaborated with SMEs, such as L'Earth Ltd. to conceptualise, develop and retail new 3D Printing bio-materials, in which the product and packaging were recognised with an International WorldStar Award in 2014 for Design excellence. He continues to advise SMEs including Quinteassential Ltd. and Watson EP Ltd. for New Product Development projects. Between 2013-2014, he collaborated and delivered projects for the Leicester Arts and Museum Service where important historical artefacts from the Anglo-Saxon and Roman period were completely digitised and faithfully reproduced using 3D Printing. He worked with the Leicester Transport Heritage Trust to undertake projects such as to completely reverse engineer a historically important Tramcar that was accurately scaled down and 3D Printed. In 2015, he was invited to lead a Masterclass at the Royal College of Art (RCA) for the Include2015 conference on the use of 3D Printing that could support Design practice. Professional Design Career As a Product Design Engineer, Eujin holds numerous Design awards, including the Wearable Master and Field Trial Winner for the Manchester Numbers That Matter Hackathon (2014), International WorldStar Packaging Award (2014), IDSA IDEA Award (2011), Helen Hamlyn Centre for Design 24 hour Inclusive Design Challenge (2011), Motorola Motofwrd (2006), Opus Eyewear (2006), UK Lighting Competition (2006), RSA Design Directions (2005), Popular Science / Core 77 Security Design Competition (2004) and the President's Furniture award (2003). His work has been published in leading international magazines such as Dwell, Icon, FX International and in national newspapers. He has also been interviewed on BBC Radio Leicester and on Power 98FM. Eujin was invited as a judge for the British Promotional Merchandise Association Design competition in 2010. He has exhibited at an international level, including MagicChef at the Panasonic Centre in Tokyo, Japan (2003); and the Clamplight at the NEC Lighting Show in Birmingham, UK (2007). In 2018, his Soundsphere project was exhibited at the Cooper Hewitt, Smithsonian Design Museum which is the only museum in the USA devoted exclusively to historic and contemporary Product Design. 

Related Research Group(s)

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Additive Manufacturing and 4D Printing - The Additive Manufacturing and 4D Printing Research Group seeks to understand the fundamental aspects and applications of programmable materials through layer-wise methods of production.


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Project last modified 13/10/2023