1.2. SUBMITTING CATEGORY

2.1 PRODUCT TITLE AND DESCRIPTION

Tilly Tote.

The Tilly Tote is a flat pack gardening kit built with a nutritious life-cycle and healthy lifestyle in mind. The kit can be described as more than a sell-able product, but rather, a multifaceted educational program.

All of the included tools are designed to encourage family gardening in order to educate a new, cleaner generation. Growing and learning activities are brought right to your backyard. Literally! In order to reduce packaging pollution, Tilly Tote was designed with a specific constraint: to be wrapper and packaging free. The fabric of the bag itself is creased at specific folding points in order to transform back and forth between tote and shipping envelope. The child’s name and shipping address are printed with biodegradable ink directly onto the fabric, serving a functional use while giving the tote unique name personalization.

Encouraging family gardening in order to educate a new, cleaner generation

1.1 CONTACT INFORMATIONMorgan Matt Virginia Tech

morganm8@vt.edu(860)808-4563

302 North Main St. Unit 4Blacksburg, VA 24060United States

Student

Autodesk Fusion 360 Aluminum

YESYES

Upon arrival in the mail, 2D aluminum gardening tools are thoughtfully nested together, making a fun building activity for the family! Specific perforations in the metal make for easy, one-time bending into 3D tool heads! Assembly instructions can be found printed on plantable veggie seed paper. Once the tools and tote are constructed, the instructions can be torn along the perforations and planted for some delicious, home-grown veggies! Gardening not only encourages healthy nutrition, but teaches kids responsibility and cooperation; skills and knowledge needed in order to work towards a cleaner generation, healthier lifestyle, and future.

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PRODUCT STORYBOARD From User’s hands back to Earth

1. Tilly Tote arrives right to the user’s home through the mail!

2. On the backside of the mailer, overlock stitching can easily be undone by snipping the end tab and pulling through.

3. The flaps can be unfolded to reveal a gardening kit inside! Contents include: printed seed paper instructions, 3 aluminum tool heads, 3 aluminum rings, and 3 bamboo handles.

The User can look to the seed paper for easy-to-follow assembly instructions for each of the gardening tools.

4. The first step in assembly involves bending the tool heads. The aluminum pieces are perforated along specific fold lines, allowing an easy transformation from 2D to 3D.

5. Separately the metal rings can be fit onto the threaded extrusion of the bamboo handles. Once in place, the file end of the tool head is inserted with a friction fit through the metal ring and into the bamboo. The threaded ring twists and locks to ensure the tool head stays in place.

6. Now that the envelope is empty, unfold remaining flaps and flip the bag pattern over to the colored side.

7. The bag can then be assembled with three easy folds and secured with the aligned bamboo buttons. (Instructions can be found on the seed paper).

8. Fold the seed paper along the perforated lines and tear to separate. (Each section has a different type of vegetable).

9. Sectioned seed paper can be placed in the soil with new tools and watered thoroughly. With sun and proper care, the family can reap the benefits of fresh veggies right from their own backyard!

2.1 PRODUCT DESCRIPTION

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Sourcing LocalExtraction of raw material is often the most carbon intensive process. The natural materials for Tilly Tote are sourced from local farmers, therefore supporting local communities and the environment. Sourcing locally, significantly reduces fuel burned in transportation, encourages use of local farmland, reduces chemical use for soil preservation, and creates overall fair working conditions

Maximizing Raw MaterialAll of the materials used to manufacture Tilly Tote are used to capacity, ensuring that even cut-offs, residues, and by-products are not wasted. The soy bean in particular, is used in several steps of the production line. While soy fiber from the plant is used as feed for local sheep, (then used for felt), the extracted oils and by-products are used to create soy ink (for printing instructions), soy fabric, soy milk dyes (for coloring fabrics), and soy based adhesive for bamboo blanks

2.3. ILLUSTRATION OF PRODUCT’S SYSTEM ECO-MANUFACTURING: Renewable energy & Water stewardship

Soy Feed Soy By- Product

Sheep

Shearing

Felt Manufacturing

Die- Cut Felt & Soy Fabric

SewBamboo Buttons

& Tote

Soy Milk Dye Mix Production

Soy FabricManufacturing

Soy Ink Production

Instructions & Shipping Printed on Seed Paper & Tote

Seed Harvest Vegetable & Flower

Seed PaperBlend Pulp & Seeds

Bamboo Harvest

Bamboo Plank Production

Recycled AluminumCollection

Tool HeadsCut & Perforated

MilledAluminum Rings

Tool Kit Combine Bamboo &

Aluminum Parts

Fold & Seal Sew edges shut with

tools and seeds inside

Home Delivery Re-Construct Garden & Play!

De-construct Separate Materials Decompose

Veggies, Wool, Soy, & Bamboo

Biological Nutrients

To Soil

Technical Nutrients

Up-cycled Aluminum

SoilBio-Nutrients

Metal Sheets

Milled Bamboo Tools

Purified Effluent WaterThe manufacturing process of fabric eliminates carcinogens and toxins up-front. Wool fibers are taken straight off the sheep with no post-processing or dyes applied. After washing and needle punching, the water is healthy enough to leave the factory. Meanwhile, soy inks off fabric production reach a dual-tank designed to trap ink and emulsion solids before they reach outflow. Such systems have been noted to potentially leave the water cleaner than when it arrived. [ see #4 for the what water is reused in the system]

Dye Fabric Fiber Reactive Dyeing

Close-Looped System: Maximizing Natural EnergyA water-jet process is used to cut aluminum tool heads. No cooling or lubricating oils are used, meaning there are no chemically contaminated chips to dispose of. (The jet stream also allows nesting to maximize material utilization) Water and abrasive can be reused several times in a closed loop system with filtration. Likewise, the water used in production of soy fabric can be filtered back and reused many times over

Re-purposing “Waste” After forming the bamboo blanks, the leftover shavings and pulp are used to blend with veggie and flower seeds; then dried on racks to create plantable paper (with soy ink instructions for assembly by consumer)

Geothermal Heat & Recovery for EnergyLow heat from a geothermal drying kiln is used to dry the bamboo blanks and plantable paper-resulting in lower emissions and energy costs to the company. Any radiated or excess heat is captured [by waste heat to power (WHP) process] to generate new energy; providing power to other processes such as die-cutting.

Recycled & Up-cycled Aluminum In acquiring aluminum in early production, the material can easily be recycled from other products. Once Tilly Tote tools reach end of life, materials are taken back to the supply chain to be reused and given equivalent value. [also negating need for further virgin stock]

Reduced Carbon FootprintAll parts of the product (tools, bag, instructions) are flat packed and delivered straight to the consumer’s home; reducing carbon footprint in more than one way!

Tilly Tote

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Raw Material Raw Material

Raw Material

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3.0 REUTILIZATION CYCLE & BUSINESS MODEL

REUTILIZATION CYCLE

Once Tilly tote has reached the end of its life, the company will support a low priority postage system in order to recover materials. A return shipping label will have already been printed on the bag (on the proper flap opposite from the consumer’s address). [#0.] It is encouraged that the consumer repack the materials in the bag with a simple overlock stitch and place in their mailbox to be shipped back out! Should the tote not be returned by mail, materials can still be recycled by other means. [#2.] [#2.] Separating bamboo and aluminum can be done by simply untwisting the threading of the aluminum ring and pulling out the tool head. [#2.] Likewise, felt and soy fabric can be separated easily by using scissors to undo the overlock stitching on the boarder. [#3.] The wool, soy fibers, and bamboo are 100%biodegradable and would be broken down at a local municipality-composting site. The non-toxicsoy/bio-dyes used on the soy fabric and thread wouldnaturally decompose as well, without harm to the environment. [#4.] The bio nutrients returned back to the soil would provide food for new soy seeds to germinate (as well as bamboo) [#5.] Once harvested the soybeans could be separated to provide oils for inks and feed for sheep! [#5.] Wool grown on the sheep, by-products from the soy, and bamboo could then be sent through the manufacturing process once again to create more fabric and tools.

On the technical nutrient side, aluminum can be infinitely recycled. [#3.] The tool heads can be dropped into curbside ,public space recycling bins, or at local recycling drop-off. [#4.] Once collected and crushed, the aluminum will be melted into ingots. [#5.] In a rather short time frame the aluminum can be used to make new products or up-cycled to the manufacturing site to be used for new tools! That means more Tilly Tote kits for gardening!

Where the raw materials are sourced from holds just as much importance as Tilly Tote’s destination. All materials used in manufacturing are to be sourced from local Farmer’s, supporting the local economy and environment. The product concept is heavily inspired and influenced by the ever-growing Farm-To-Table movement. As such, the business lives by the morals and standards behind its culture, including sustainable agriculture and the tight-knit link between customers and farmers. Local jobs increase while the pollutants sourcing raw materials are significantly reduced.

Tilly Tote is designed with the environment in mind, but more-so, to educate the people who share our planet. From immediate arrival in the mail, the tote’s disguise as packaging serves an important and exciting lesson. User’s will grasp an understanding for sustainability and the overuse of packaging, as it is not needed at all with a little design intention!

The product’s main purpose as a gardening kit provides a bonding experience for families and encourages outdoor play. While caring for plants and collecting fresh veggies, kids can learn about science, nature, personal nutrition, and the importance of our surroundings. Helping kids develop a love for nature and value for the environment is a mission that lives in the heart of the Tilly Tote Brand.

BUSINESS MODEL

Tilly Tote is made from six homogeneous materials. [1.]The Eco-felt made from natural, untreated wool fibers is completely biodegradable and provides structure (and protection in shipping through mails) with thickness. Wool holds many other beneficial features for gardening since it is anti-bacterial, weather resistant, and sturdy.

4.1 OVERVIEW:

[2.] Bamboo is a readily renewable resource that is cost effective. (As a designer I was extremely determined to be tree-free). The material is anti-bacterial, water-resistant, and durable; all excellent traits for the tool handles. [3.] Soy Fabric is made from the by-product of soy oils (the hulls)- a plant particularly known for its many uses. The plant is a renewable resource that can be grown organically and maximized in use (as it is with animal feed, ink production, and bamboo adhesive here). The fabric is also anti-bacterial and safe to place veggies in! [4]. Biodegradable ink used on the soy fabric and plantable paper is readily absorbed producing beautiful, bright, and readable color that’s safe for the environment. [5.] A variety of vegetable seeds are used in the instructions paper (with bamboo pulp and bio-ink) and go directly into the soil to grow. [6]. Aluminum used for the tool heads and rings can be readily resourced and infinitely recycled.

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4.3. Material Health:

Eco-Felt (Organic wool)is not chemically treated during the entire production process, from the farm to the finished garment or product. The USDA National Organic Program (NOP) has created strict standards for producing and processing agricultural products to be sold as organic in the US. In order to ensure that these standards are being met, the NOP has accredited about 50 organizations throughout the world as organic certifiers. Additionally, the material is both Fire Resistant and Anti- bacterial. [healthychild.com & msdsmanagement.com]

AluminumNFPA health score 0.”Health-0Flammability-0Reactivity-2Exposure-0Storage-0[www.flinnsci.com]

Bamboois a member of the grass family which has distinct anatomical differences from wood. Therefore bamboo would be regulated as an organic dust in a category otherwise known as (PNOR) “Particulates Not Otherwise Regulated, or Nuisance Dust by OSHA. The only noted health hazard is in dealing with dust during manufacturing- Bamboo is otherwise, a natural and safe material. [MSDS bamboo flooring]

Soy Fabric is non-hazardous and is not classified as a Dangerous.Traditionally many pesticides have been used for cultivation, but organic soy can successfully be grown on a smaller, more lower-impact scale (as used here). [MSDS www.adm.com]

Bio-Degradable Dies only use certified organic clays & vegetables (soy). These dyes would be both safe for the user to interact with and would be biodegradable. [www.biodye.in].

Tilly Tote.Encouraging family gardening in order to educate a new, cleaner generation

4.2. Material Reutilization:

Tilly Tote bag is design for disassembly and uses 100% recycled or renewable content. The whole product kit has a Reutilization Score of 100, allowing the bag to be eligible for platinum C2C certification

5. Design with Autodesk’s Fusion 360™:

While it is extremely important to design in a physical sense with sketching and rapid prototyping, Fusion 360 allows for a rapid, accurate, and easily altered 3-dimensional model. Although I had already developed my idea through sketching and some cardboard mock-ups, the finer calculations for sizing and fittings for the gardening tools came into play with Fusion. Being able to type in numerical values made it possible to make minor tweaks time and time again, finding the right ergonomic dimensions for a child’s hands (based on anthropometric data) while simultaneously working towards a model with the “least amount of material needed”. Not only was this a time-saver guaranteed for accuracy, but it meant using less material in the long run for minor alterations. The number of alterations I made on Fusion would have ultimately added up to 20 foam mock-ups. Fusion made is extremely easy to scan my drawings (and cardboard models) and mold the handle 3-dimensionally to the proper outlines. Making minor tweaks to an original mold was far easier for me; someone who doesn’t have as much success with entirely math based CAD programs. I additionally used the 3D model of Fusion in order to create perfect matching threading between the bamboo handles and the aluminum ring attachments; getting a perfect match was essential for the system to work. Because the overall system is cloud-based, working in a group would be much easier than a traditional (non-cloud based) program. Components could be created by members of the team and, most importantly, design ideas could be easily and visually communicated to the group from a distance. This would prove particularly beneficial if sharing the online link with a manufacturer. Working together to fit the tooling while maximizing nesting for their machines could be edited by the manufacturer directly. This would be important from a financial standpoint but, more importantly, in minimizing waste. The handle and ring here would need to be milled while the flat tool heads would need to be water jet. Since I plan to seek investors/crowdfunding for a prototype post competition, I’ll be using (a version) of this Fusion CAD model for manufacturing!