I. Materials
Michael Lau
Ashwin Halepet, Nicholas Hann
DES 40A
Professor Cogdell
Life Cycle of Apple Vision Pro Camera: Raw Materials
The Apple Vision Pro is a brand new spatial computing device released by Apple in 2024. This device is worn as a headset and weaves reality with a digital landscape to create a unique user experience. The Vision Pro captures reality through its many cameras and displays it to the user through screens. This report aims to detail the life cycle of these components. The life cycle of the Apple Vision Pro's cameras involve the acquisition and processing of raw materials. The introduction of raw materials is most heavily involved in their acquisition and processing steps, but some new materials must also be introduced in distribution, maintenance, recycling, and waste. All of the materials used at every step will be accounted for in this life cycle analysis.
The raw materials required for manufacturing the cameras’ electronics and optics come directly from the Earth across many different locations. The electronic components that provide the power and computation for the cameras are generally placed on printed circuit boards (PCBs). PCBs are made up of silicon integrated circuits, copper wires, and fiberglass (Ai; Belle). The silicon used in electronic circuits, called metallurgical-grade and electronics-grade silicon, usually comes from quartzite (“Semiconductor Grade Silicon”). Quartzite and other high-purity silicon minerals are mined most from China (“Mineral Commodity Summaries”). These raw materials are processed into a secondary raw material called polysilicon by the Siemens process, in which powdered silicon undergoes chemical reactions with hydrogen chloride and hydrogen gas; and next it is further purified by growing silicon crystals by chemical vapor deposition (“Semiconductor Grade Silicon”). Polysilicon is essentially pure silicon polycrystals, but for electronics, single-crystal silicon is required for excellent control of electronic properties. This means that an extra processing step is required to produce single crystal silicon. A common industrial process for producing single-crystal silicon is called the Czochralski method. In this process, polysilicon, and small quantities of impurities called dopants (such as boron or phosphorus are melted in a large, rotating crucible, and then a small seed crystal of silicon is held at the top of the melt (“Semiconductor Grade Silicon;” Sequeda). The molten silicon begins to grow a large single crystal from the seed crystal until a large cylindrical ingot of silicon is produced. After these ingots are formed, they are moved to clean rooms for further processing. The ingots are sliced into thin wafers, then these wafers are further processed by patterning and etching to form desired electronic components down to the nanometer scale (Sequeda). These completed silicon wafers are then cut down to size and packaged as integrated circuits. These integrated circuits can then be soldered directly to printed circuit boards. To allow for communication between different integrated circuits, wires are needed to physically connect components. Typically, these wires are made of copper. Copper ores are mined across the world; major copper mining countries include: Chile, Peru, Congo, China, and the U.S. (“Mineral Commodity Summaries”). However, the majority of copper is refined in China (“Mineral Commodity Summaries”). The processing of copper ores falls under one of two categories, depending on the chemical composition of the ore. Copper oxide ores are processed by hydrometallurgy (“Copper Mining Processing”). This process requires sulfuric acid to be added in order to dissolve copper ions into a solution. These ions are separated and precipitate onto a copper cathode through an electrochemical reaction, which forms pure copper metal (“Copper Mining Processing”). Copper sulfide ores are processed by pyrometallurgy (“Copper Mining Processing”). In this process, copper ores are crushed very finely and added to a liquid so that a slurry is formed. Chemicals added to the slurry cause copper sulfide compounds to separate from the slurry, and these are removed by air bubbles. These compounds are then thickened and smelted at 2300 ℉ to form large impure copper slabs. To complete purification, electrolysis is performed between the impure copper slab (anode) and a pure copper slab (cathode). The copper from the anode enters electrolyte solution and deposits on the pure copper slab, and it is this cathode that is the refined copper product. From this, copper can be rolled or drawn into sheets or wires, respectively, that are added to PCBs. The copper wires and integrated circuits are all placed on fiberglass substrates. Fiberglass is a composite material made up of glass fibers woven on an epoxy matrix (Ai). Glass fibers are long strands of glass that are drawn from molten glass. Molten glass is produced mainly with silica sand, which is a special type of sand that is high in silica content. This resource mainly comes from the U.S. and China (“Mineral Commodity Summaries”). Additives such as boron are also combined with the molten glass in order to help it be less viscous (Tojo). Epoxy is a thermoset plastic that is formed with chemical reactions containing bisphenol A (BPA), a product from petroleum refining (Tsai). The fiberglass composite provides a strong and lightweight substrate for the integrated circuits and copper wires. Aside from the electronics, the optics for these cameras are also made from glass. However, camera lenses are made with sapphire glass, which is not silica based. Sapphire glass is a lab-grown sapphire crystal made from aluminum oxide (alumina), which is a processed material from bauxite, an aluminum ore. Bauxite is mined from Australia, China, and Guinea (“Mineral Commodity Summaries”). Alumina powder from bauxite is melted and undergoes the Czochralski method, the same as for making pure silicon ingots (Khattak). Then, like silicon, the glass is cut down to the correct size and geometry for the camera’s optics. The optics and PCBs are held in place and given structure by polycarbonate casings. Polycarbonate is a plastic also synthesized with BPA, thus it is also a petroleum based plastic (“Potential Alternative Polycarbonate”). Polycarbonate is formed into desired shapes by an injection molding process, as it can be heated and softened, then hardened to the desired shapes (Wang). All of these materials make up components that, when combined, allow the Vision Pro’s cameras to function.
The Vision Pro’s cameras and their components must be shipped across the world for further assembly of the final product. The transportation of these products involves the introduction of new raw materials for two distinct categories: packaging and fuels. Packaging of the Vision Pro and its components involves paper products, such as cardboard. Apple claims that “100%” of its packaging is fiber based “to eliminate plastic in packaging” (“Product Environmental Report”). Apple states that its raw materials come from sustainably managed forests, indicating that the raw material is wood (“Product Environmental Report”). Apple also notes that the shipping methods they use are “less carbon-intensive,” including “rail and ocean transport” (“Product Environmental Report”). The fuels that trains and container ships use are typically diesel, but some container ships also use heavy bunker fuel, which is a very pollutive petroleum fuel (Gallucci). Petroleum and wood are the two most important raw materials required for the transport of the Vision Pro’s cameras.
The Vision Pro’s cameras get to the hands of consumers as the final assembled Vision Pro headset. Other raw materials present in the Vision Pro headset are metals such as aluminum and stainless steel, as well as other petroleum based polymers like nylon, polyester, polyurethane, spandex, and other elastomers (“About the Materials”). These materials make up other components of the Vision Pro, like the head strap, casings, and seals. During regular use, the product is designed to be durable and long lasting, but if repairs and maintenance are needed, parts can be replaced due to mass production. These parts all will use the same materials as was used in the initial production of the Vision Pro.
However, once the Vision Pro has degraded over time, it must be disposed of properly. The cameras inside the Vision Pro have some recyclable materials, while others are disposed of as waste. Some components of the PCBs in the Vision Pro can be recycled. One emergent technique of recycling the PCB is dissolution (Chen). In this process, new materials must be introduced in order to dissolve the fiberglass substrate of the PCB. The solvent is made up of ethylene glycol, organic solvent, and transesterification catalyst. The addition of this solvent causes the fiberglass substrate to swell, allowing more solvent to enter and erode the epoxy matrix (Chen). This separates the epoxy from the glass fibers. The glass fibers retain most of their structural integrity, and can be reused (Chen). This process also separates all of the electronic components from the substrate. It is the separation of materials that allows for recycling, as each different material has its own specific recycling method. The copper used in PCBs, once isolated, is extracted and recycled using the same dissolution and electrochemical reaction as mentioned in its refining process (“Printed Circuit Recycling”). The electronics-grade silicon in the integrated circuits cannot be recycled due to the presence of chemical dopants and the integrated circuits’ complex, specific designs (Oliver). However, these integrated circuits could be reused between devices, given similar processing tasks are shared between the Vision Pro and its acceptor device, typically at a lower processing power (Oliver). Otherwise, the integrated circuits are simply placed in the landfill. The glass in the optics can be recycled as well. Sapphire glass can be melted down again to supply growing new crystals by the Czochralski method, mentioned previously (Khattak). Polycarbonate can be recycled by dissolution. New raw materials are introduced at this step: N-methylpyrrolidone and dichloromethane (Yu). Water is also required for this process (Yu). This process recovers about 90% of the polycarbonate, but that means 10% of it is lost and must be disposed of as chemical waste (Yu). The majority of the materials from the Vision Pro’s cameras can be recycled back to the beginning of a new product, excluding the silicon which must be placed in a landfill.
From the acquisition of raw materials, through processing, distribution, maintenance, recycling, and disposal, the life cycle of the Apple Vision Pro involves many shared materials between steps, allowing for the end of life of one device to begin the life of another. Many of the materials being recycled shows a step towards better sustainability, limiting the raw materials that must be reacquired from the Earth.
Works Cited
“About the materials used in Apple Vision Pro.” Apple, 28 February 2024, https://support.apple.com/en-us/118475.
Ai, Bing and Hu, Biao. “PCB Board, Core for Manufacturing the PCB Board and Method for Manufacturing the PCB Board.” US9226404B2, 29 December 2015, https://patents.google.com/patent/US9226404B2/en.
Belle. “Printed Circuit Board ≠ Integrated Circuit, Make No Mistake.” iPCB, 28 September 2021. https://www.ipcb.com/ic-substrate-tech/3338.html.
Chen, Zhiqiang, et al. “Recycling Waste Circuit Board Efficiently and Environmentally Friendly through Small-Molecule Assisted Dissolution.” Scientific Reports, vol. 9, no. 17902, 2019. https://doi.org/10.1038/s41598-019-54045-w.
“Copper Mining and Processing: Processing Copper Ores.” University of Arizona, 2024, https://superfund.arizona.edu/resources/learning-modules-english/copper-mining-and-processing/processing-copper-ores.
Gallucci, Maria. “The Struggle to Make Diesel-Guzzling Cargo Ships Greener.” IEEE Spectrum, 29 May 2018, https://spectrum.ieee.org/the-struggle-to-make-dieselguzzling-cargo-ships-greener.
Khattak, Chandra and Schmid, Frederick. “Growth of the World’s Largest Sapphire Crystals.” Journal of Crystal Growth, vol. 225, no. 2, 2001, pp. 572-579, https://doi.org/10.1016/S0022-0248(01)00955-1.
“Mineral Commodity Summaries 2024.” U.S. Geological Survey, 2024, https://doi.org/10.3133/mcs2024.
Oliver, John Y., et al. “Life Cycle Aware Computing: Reusing Silicon Technology.” Computer, vol. 40, no. 12, 2007, pp. 56-61, https://doi.org/10.1109/MC.2007.433.
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Tojo, Shin and Kimura, Miki. “Production Method for Borosilicate Glass.” WO2017110906A1, 29 June 2017, https://patents.google.com/patent/WO2017110906A1/en.
Tsai, Wen-Tien. “Survey on the Environmental Risks of Bisphenol A and Its Relevant Regulations in Taiwan: An Environmental Endocrine-Disrupting Chemical of Increasing Concern.” Toxics vol. 11, no. 9, 2023, https://doi.org/10.3390/toxics11090722.
Wang, Xinyu, Li, Zheng, Gu, Junfeng, et al. “Reducing Service Stress of the Injection-Molded Polycarbonate Window by Optimizing Mold Construction and Product Structure.” The International Journal of Advanced Manufacturing Technology vol. 86, 2016, pp. 1691–1704, https://doi.org/10.1007/s00170-015-8278-5.
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II. Energy
Halepet, Ashwin
Hann, Nicholas; Lau, Michael
DES 40A
Professor Cogdell
Life Cycle: Energy
The Apple Vision Pro is one of the newest headsets for virtual and augmented reality (AR). In order to achieve a clear image in augmented reality, the Vision Pro possesses 12 cameras (Apple.com, 2024) and combines the data from each to create a display that aims to be indistinguishable from true eyesight. The creation, utilization, and disposal of these cameras uses a lot of energy. As one of the top products in the field of AR from one of the largest tech companies, it is important to know where and how that energy is being used. As such, this section will go into detail on the energy usage of every stage of production of the cameras and lenses of the Apple Vision Pro.
First, the main visor is made of one piece of laminated glass that covers the cameras, which, as a system, have a resolution of 6.5 megapixels (Apple.com, 2024). These cameras do not yet have exact specifications, but they are similar to smartphone cameras, which are made of a lens of either plastic or glass and a sensor made of silicon. Since the main visor is laminated glass, a combination of glass and plastic, we can assume the main raw materials are sand for the glass, oil for the plastic, and silicon.
Both sand and silicon are mined from the same source (Goodin). According to the Department of Energy, the energy to mine this comes from a combination of natural gas, gasoline, diesel, coal, and electricity derived from any nearby sources (U.S. Department of Energy, 2007). These nearby sources may or may not be renewable, but in total there is at least 68% of energy consumption from fossil fuels. Plastic is produced from oil and also uses primarily natural gas as an energy source (Marczak, 2022).
After the materials are mined, they must move to the factories to get made into parts and assembled. Once they are, they move onto distribution centers to be sold in Apple stores. Apple already has factories to build and assemble these items. According to Lifewire, cameras are made in Japan and glass screens are made in the US (Costello, 2021). All of these parts are then sent to Taiwan to be assembled.
While there aren’t exact numbers for the energy used at these facilities, Apple factories are currently on track to use 95% of their energy from renewable sources by 2030 (Apple, 2022). Specifically, in 2021, the renewable energy section of their supply chain used 18% by solar power and 61% by wind power, with the last 21% using biomass, geothermal, or other renewable sources. These sources are used for both manufacturing and distribution. Currently, due to lack of transparency by Apple, there is no number for the amount of nonrenewable energy that is used now.
After the Vision Pro is sold, it uses electricity to charge its lithium battery. The source of this electricity is dependent on the user, but the amount of energy stored and used is the same for each device. According to the technical specifications of the Vision Pro, the headset can be used for 2 to 2.5 hours (Apple.com, 2024). Independent testing has shown that it takes 1.5 hours to recharge the battery (Hall, 2024). Given that Apple recommends using an adapter rated for 30W (Apple Support, 2024), this means that the Vision Pro uses 18-22W of power. For comparison, according to Forbes, an iPhone battery holds 5.45 Wh of energy and over the course of 6-10 hours to run that battery, this means an iPhone uses 0.5-0.9W (Hellman, 2024).
Finally, after a user is done with their Vision Pro, whether it be that it stopped working or to trade in for a hypothetical newer model, they will need to trade it into an Apple store to be recycled. Once it’s recycled, an estimated 20% of this material will make its way back into more Apple products (Apple Newsroom, 2022). According to a Globus case study, all of Apple’s recycling facilities are 100% based on renewable energy (Beckett-Hester, 2021). However, the remaining 80% of material still goes somewhere. In 2021, Apple converted 32% of its landfill waste to energy or compost (GlobalData, 2021) with the remaining 68%, or nearly 940 tons of waste going to landfills. It is reasonable to assume the Vision Pro will be lumped in with the rest of Apple’s products.
While Apple has been making great steps recently with regards to the environment in its energy usage, there are many factors they fail to disclose in order to hide inevitable uses of fossil fuels, such as in mining, transportation, and waste. Additionally, the Apple Vision Pro specifically uses a great amount more power to run than other Apple products, meaning that the energy cost to use the Vision Pro is disproportionately high for what it is. For waste, even though Apple claims to use recyclable materials, much of the material of the Apple Vision Pro is not recycled in the end anyway.
“Apple Expands the Use of Recycled Materials across Its Products.” Apple Newsroom, Apple, 19 Apr. 2022, www.apple.com/newsroom/2022/04/apple-expands-the-use-of-recycled-materials-across-its-products/.
“Apple Vision Pro - Technical Specifications.” Apple, Apple, 2024, www.apple.com/apple-vision-pro/specs/.
“Apple: Waste Generation in 2021.” GlobalData, John Carpenter House, 2021, www.globaldata.com/data-insights/technology-media-and-telecom/apple-waste-generation-2095979/.
Apple’s Supplier Clean Energy Program Update, Apple, 2022, www.apple.com/environment/pdf/Apple_Supplier_Clean_Energy_Program_Update_2022.pdf.
Beckett-Hester, Finn. “The E-Waste Problem: A Case Study of Apple.” GLOBUS, GLOBUS, 15 Jan. 2021, globuswarwick.com/2021/01/21/the-e-waste-problem-a-case-study-of-apple/.
“Connect and Charge Apple Vision Pro Battery.” Apple Support, Apple, 8 May 2024, support.apple.com/en-us/117740.
Costello, Sam. “Where Is the Iphone Made? (It’s Not Just One Country!).” Lifewire, Lifewire, 27 Jan. 2021, www.lifewire.com/where-is-the-iphone-made-1999503.
Goodin, Robert C. “Silica Statistics and Information.” Silica Statistics and Information | U.S. Geological Survey, National Minerals Information Center, www.usgs.gov/centers/national-minerals-information-center/silica-statistics-and-information. Accessed 4 June 2024.
Hall, Zac. “Apple Vision Pro Battery Life Test Results: Under Promise, Slightly over Deliver.” 9to5Mac, 30 Jan. 2024, 9to5mac.com/2024/01/30/apple-vision-pro-battery-life-charge-time/.
Helman, Christopher. “How Much Electricity Do Your Gadgets Really Use?” Forbes, Forbes Magazine, 3 June 2024, www.forbes.com/sites/christopherhelman/2013/09/07/how-much-energy-does-your-iphone-and-other-devices-use-and-what-to-do-about-it/?sh=bdeb4a52f702.
Marczak, Halina. "Energy Inputs on the Production of Plastic Products." Journal of Ecological Engineering, vol. 23, no. 9, 2022, pp. 146-156. doi:10.12911/22998993/151815.
U.S. Mining Industry Energy Bandwidth Study, U.S. Department of Energy, June 2007, www.energy.gov/eere/iedo/articles/us-mining-industry-energy-bandwidth-study.
III. Waste and Pollution
Nicholas Hann
Group1 - Michael Lau, Ashwin Halepet
Cogdell
DES 40A SPRING 2024
The Life Cycle of Apple Vision Pro AR Lenses: Waste and Emissions Analysis
Introduction
The Apple Vision Pro, an innovative and futuristic device, has set new boundaries in computing and virtual reality (VR). As a goggle-like device, it integrates advanced technologies to create an immersive user experience. However, the convenience and sophistication of such devices come at a significant environmental cost. This paper delves into the life cycle analysis (LCA) of the AR lenses in the Apple Vision Pro, focusing on waste and emissions from manufacturing to disposal. Specifically, it evaluates the waste generated and emissions released throughout the production, usage, and end-of-life stages of the AR lenses, highlighting Apple's efforts to mitigate these impacts and proposing further improvements. By examining the environmental impact of these components, we aim to understand the broader implications of producing such high-tech gadgets.
Extraction and Manufacturing
The production of AR lenses for the Apple Vision Pro begins with the extraction of raw materials. The primary materials include silica, silicon, and various rare earth elements, which are essential for manufacturing microchips and other electronic components. The extraction process itself is resource-intensive, requiring substantial amounts of water and energy. For instance, silicon, a key component, is derived from silica found in sand. The refining process of silicon is energy-intensive, involving high-temperature furnaces that consume large amounts of electricity, predominantly sourced from fossil fuels . During manufacturing, the production of microchips for AR lenses generates significant waste and emissions. Mining of these materials is energy-intensive and leads to significant carbon emissions, water contamination, and habitat destruction. For instance, the extraction of silicon involves processes like carbothermic reduction, which emits substantial amounts of carbon dioxide (Williams et al.). Chemical solvents and gasses used in the etching and cleaning processes contribute to hazardous waste into our water streams. According to Williams et al. The production of a single 2-gram microchip can involve as much as 1.7 kilograms of fossil fuel and chemical inputs, leading to substantial environmental pollutants . These emissions include volatile organic compounds (VOCs), particulate matter, and greenhouse gasses (GHGs), all of which have damaging effects on air quality and climate change. Another stage in the manufacturing process is Semiconductor fabrication. It is notorious for its high energy consumption and the generation of copious amounts of chemical waste. Starting at the issues with extraction for these materials it then turns into another issue, what we then do with all the byproducts.
Waste and Recycling in Manufacturing
The manufacturing phase of AR lenses generates various byproducts that pose environmental challenges. Effective waste management is crucial in mitigating the environmental impact of AR lens production. Apple has implemented several programs to address the waste generated throughout the product's life cycle. Their free-recycling program is a notable initiative, encouraging consumers to return old devices for recycling (Apple). This program aims to recover valuable materials and reduce electronic waste (e-waste), which is a growing global concern. Recycling AR lenses involves recovering rare earth elements and other valuable materials from discarded devices. Reyna et al. emphasizes the importance of developing efficient recycling technologies to extract these materials, reducing the need for new raw material extraction and minimizing environmental impact. Apple's recycling initiatives reflect a commitment to a circular economy and that cradle to cradle system, where materials are reused, reducing waste and conserving natural resources. In the instance of the Vision pro, the aluminum used in the Vision Pro's casing is sourced from 100% recycled aluminum, significantly reducing the environmental footprint of the device. After we figure out what to do with all the byproducts of manufacturing, you also have to take into account what happens to that whole device after its consumer use.
E-Waste and End-of-Life Management
As electronic devices like the Apple Vision Pro reach the end of their useful lives, they contribute to the growing problem of electronic waste (e-waste). Perkins et al. states that E-waste contains hazardous substances such as lead, mercury, and cadmium, which can leach into the environment if not properly managed, which can cause severe environmental and health issues. According to the United Nations University, e-waste generated globally reached 53.6 million metric tons in 2019, with only 17.4% being recycled properly. Apple's recycling program aims to address this issue by encouraging consumers to return their old devices for recycling. The company has even developed a disassembly robot in 2018 , Daisy, which can dismantle iPhones and recover valuable materials, including gold, cobalt, and rare earth elements, for reuse in new products. This initiative not only reduces the environmental impact of mining new materials but also decreases the volume of e-waste.
Innovations in Recycling AR/VR Lenses
To further mitigate the environmental impact of AR/VR lenses, innovative recycling techniques are essential. Research is ongoing to develop methods for recycling complex materials used in these lenses. For example, advances in chemical recycling can break down polymers into their monomer components, which can then be reused in new products. The development of biodegradable electronic components holds promise for reducing the long-term environmental impact of electronic devices. Apple's commitment to a circular economy is evident in its efforts to design products that are easier to disassemble and recycle. By using modular designs and reducing the use of adhesives, Apple enhances the recyclability of its devices. Furthermore, the company invests in research to improve recycling technologies, ensuring that more materials can be recovered and reused . It’s also important to think of technological obsolescence. To further reduce the environmental impact of AR lenses, it is essential to advocate for anti-obsolescence and promote the long-term use of products. Designing products with longevity in mind can significantly reduce waste and emissions associated with frequent upgrades and replacements. Apple has made progress in this area by providing software updates for older devices and offering repair services to extend the lifespan of its products. In addition to exploring alternative uses for AR lenses and their components this can contribute to sustainability. For example, repurposing AR lenses for use in other devices or applications can reduce the demand for new materials and minimize waste. Research into developing biodegradable or more easily recyclable materials for AR lenses is also crucial for future sustainability efforts (Saleh et al.).
Conclusion
The life cycle analysis of the AR lenses in the Apple Vision Pro reveals significant environmental challenges related to waste and emissions. From the extraction of raw materials to the disposal of end-of-life devices, each stage of the product life cycle contributes to environmental degradation. However, Apple's proactive measures, such as using recycled materials, improving manufacturing processes, and developing robust recycling programs, demonstrate a commitment to minimizing the environmental impact of its products. While these efforts are commendable, ongoing innovation and stricter environmental regulations are necessary to address the broader issue of e-waste and ensure a sustainable future for electronic devices.
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