This project is primarily research-based, focusing on developing new theories and processes tailored for small companies. It seeks to investigate how design principles can contribute to alternative production methods that minimize waste and enhance sustainability in the manufacturing of carbon composite mountain bike handlebars.

Previous experience from practical training at Berk Composites highlighted that material waste during production significantly impacts costs for manufacturers. The limited recycling options for disposing of these composite materials further enhance the significance of this issue, presenting a valuable opportunity for research exploration.

The problem of production waste in manufacturing is crucial due to its impact on individuals, organizations, and systems. For individuals, waste reduction leads to more sustainable products and a smaller ecological footprint. Organizations can benefit from lower production costs and enhanced sustainability, improving their market competitiveness. Systems, especially environmental and economic, gain from resource conservation and reduced landfill use.

Addressing this issue can foster innovation in manufacturing and support sustainability goals. In industries like mountain bike manufacturing, where carbon fiber is used, efficiency and environmental impact are key concerns, making waste reduction particularly beneficial.

The design philosophy for the handlebars is quite simple. Produce handlebars in the least consuming way. As recorded in the research phase, composite materials produce substantial waste during production and leave a negative attitude in the surrounding community.

To achieve this, it is crucial to be comprehensive of various theoretical methods and an open mindset towards uncommonness. Even the methods used can be altered, added, or subtracted if needed. The goal is to test and experiment with what is not conventional rather than conventional. There is no sense to experiment with established methods since there is a lot of research done already so the area of research becomes limited.

The approach for this research is methodological and simultaneously explorative. The methods can provide a good framework in the process; however, the decision-making process is personal. As mentioned before, the goal is to produce less waste during manufacturing which heavily impacts on the orientation of this project.