TOWARDS ZERO WASTE
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Tooling has a major environmental impact. A recent Life Cycle Assessment (LCA) of an IMOCA build showed that the plug and mould were responsible for 50% of the build CO2e emissions and 25% of the emissions for launching the boat. The Tooling Decision Tree, see below, has been built with input from naval architects and existing LCA studies to offer guidance on how we can all reduce our tooling impacts.
Use the reuse and recycling map to identify local solutions. If you don't have enough volume by yourself identify other stakeholders in your region with the same waste streams and organise a group collect. If you think a GiveBox style idea could work in your region (see case study link) then reach out to them over Facebook for advice and guidance.
If you have experience of a great solution, use the button next to the Solutions Database below, to share it on the platform and with the rest of the industry.
TOOLING DECISION TREE
Tooling_tree.pdf**ROADMAP ACTION**
Background
The tooling decision tree has been developed by innovation workshop particpants to help identify at what points we can make decisions to reduce the environmental impacts of tooling and moulds.
The tree offers guidance on responsible manufacturing in blue while recognising the technical requirements that drive the decisions behind full carbon moulds - which almost double the CO2 footprint of building a carbon hull.
What rules can we put in place that change the pathway and reduce out tooling impacts?
Add ideas for rules here.
Map of composite recycling solutions
Platform development targets 2022
1. Use platform to share information on existing recycling & reuse routes & possibilities
2. Provide education around the integration of recycled materials into builds
3. Use the platform to enable cross industry mutualisation of material collection to reach more efficient volumes
NOTE: Any resources on this platform that have been created as a direct result of the Innovation Workshop Series or that directly progress the Roadmap 2030 are highlighted with a **ROADMAP ACTION**
ReUse & Recycling Solutions Database
Case studies
APER The leisure boat industry
L’APER (Association pour la Plaisance Eco-Responsable) est une association de loi 1901 fondée par la Fédération des Industries Nautiques (FIN) dans l’objectif est d’animer et de structurer la filière de déconstruction des bateaux de plaisance en fin de vie.
APER (Association pour la Plaisance Eco-Responsable) is an association under the French law of 1901 founded by the Fédération des Industries Nautiques (FIN) with the objective of animating and structuring the deconstruction of pleasure boats at the end of their life.
The GiveBox, Lorient
The GiveBox Lorient is an initiative managed by Audelor and the IMOCA class to enable the reuse of equipment within the Course au Large and increase solidarity between teams of different means.
https://www.facebook.com/GiveBoxLorient
Carbon fibre recyling & resue
INEOS Britannia America's Cup Team
ELG (now Gen2Carbon) recycled the team’s carbon fibre waste from the 35th America’s Cup - which comprised of pre-impregnated and cured parts - and reprocessed those into thermoset and thermoplastic compounds and non-woven mats. Those were subsequently used in various areas of the team’s manufacturing processes, including in the manufacturing of the boat’s cradles, deck moulds and more.
Read more here and watch this video with Michel Marie explaining the process.
Carbon fibre recyling & resue
Persico Marine has developed a local carbon fibre recycling project which allows the to recycle their carbon fibre waste and reuse it in tooling.
Recycled carbon fibre demonstrates compatable thermal expansion properties which enables its use in this high impact area.
Read more here.
Carbon fibre recyling - pilot study
As it stands the marine industry is producing over 56,000 tons of carbon waste a year…
A pilot study was set up between 11th Hour Racing Team, IMOCA & Gen2Carbon. In the space of 2 months, 3.5 tonnes of carbon fibre has been collected and sent off to recycling. Diverting these materials away from landfill and back into the sailing community.
Over 6 marine industry actors along the western coast of France contributed their carbon fibre waste, as well as a handful of IMOCA teams.
Resources