Tyvek Tool Caddy – Waste Stream Product

The tool caddy stores worksite hand tools using waste Tyvek sheets commonly found on construction sites.3 Week Project as part of the Other Today Studio at University of Brighton 2nd Product Design

What have I done?

  • My project began with an interest in using a textile as the sheet material. Early on I focused on fabrics such as canvas for use in a wallet or similar application. While exploring materials, I came across ‘Mighty Wallet’; a wallet made from a Tyvek envelope. I often see Tyvek in skips so decided to research Tyvek further. Several people online have used the material for tote bags, drawstring bags and the like, however this is from virgin rolls of tyvek not offcuts. Tyvek do offer a recycling system for its products but it is highly inaccessible and offers no benefits to the construction companies.
  • This is my supply chain intercept point, providing an alternative to throwing away the material into skips. I could either remove the waste Tyvek from skips when they get sorted after collection, or work with the construction companies to set aside the Tyvek scraps to be sent via post as a bundle would be quite light. Alternatively a local rep could collect offcuts from several worksites and send it to the manufacturer in a larger bundle. This would save them money from skips costs and prevent this useful material from entering the landfill.
  • I wanted the product to stick to the materials origins as much as possible, ensuring that the product didn’t have far to be sold, so I focused on something for the worksite, such as tool storage. Storing tools on a worksite in a well organised manner is essential to an efficient building process so I saw producing a strong bag to hold the essentials from an inexpensive material as an opportunity.
  • Research into origami and different folding methods for paper worked well for finding the strongest and most space efficient storage method. The traditional method of producing pockets uses oddly shaped material and leaves the material proud which can catch and tear on worksite obstructions when not being used. The origami folds I used keeps the pockets flat when not being used.
  • Leaving it with a clean aesthetic was important such as hiding the stitches, but the strength of the joints was paramount, where these folds came into play. I also has very little waste and fold into itself to ship as its own envelope.


Material Research Ended in Tyvek being chosen as the material to be used, and further research such as stitch length and thread tension was done to ensure the best project was made.

Tyvek Supply Chain

IterationSeveral iterations were made in terms of folds and interactions between the materials. Origami techniques were changed and altered from standard variations.As I was originally going to do a wallet, some of the folds I used there could have been used in my final object.The coin wallet was a good test, in terms of strength and the types of folds that can be used.

Both tyvek and paper were used for the testing of these folds.Instructions for ManufactureBelow is the cut and fold list for the entire tool caddy. Depending the whether the end user or the manufacturer is making the caddy. It can be either hand sewn or machine sewn, which ever is avaliable.30 x 150

  1. Knife pleat fold at 50mm and 25mm
  2. Repeat once

400 x 130

  1. Knife pleat fold at 50mm and 25mm
  2. Repeat 4 times
  3. Vertical fold at 100mm

160 x 230

  1. Knife pleat fold at 65mm and 30mm
  2. Knife pleat fold at 125mm and 15mm
  3. Vertical fold at 130mm

100 x 240

  1. Knife pleat fold at 40mm and 20mm
  2. Repeat three times

740 x 80

  1. Fold in half lengthways

600 x 420

  1. Fold in half lengthways to make 600 x 210
  2. Crease every 73mm
  3. Fold vertically 10mm at the open end of long edge
  4. Cut 10mm at 73mm creases where vertical fold has been made

Final ProductFinal Product as posted on the left and as assembled on the right

Potential in the project

  • I found the material quite nice to sew and cut as it is very much like paper. It’s easy to cut square and fold in the right places. I see a lot of potential in other products that could be made with the material, from smaller items such as a safety glasses case, or stuff sacks for waterproof clothing to an entire storage rack for a van or digger. Very specific tool kits for jobs could be made in the material as tool rolls, such as a daily maintenance kit for an excavator.
  • The main benefits of using this material are of course the interception of a waste stream, with very standard sizes of offcuts. They are almost always full width offcuts, and therefore designs can easily be made parametrically according the the length of offcuts.
  • Since the material can be laser cut means these parametric designs can be simply cut out without any complications, depending on the material available.
  • Changes to the current design would include making it entirely machine sewable and placing a solid bottom into the caddy to make it more stable (although this isn’t within the brief).

Research AppendixFabric Land Brightonhttps://www.fabricland.co.uk/fabric-stores/fabric-land-brighton/Kraft Paper Walletshttps://en.pinkoi.com/magz/qLvDDOjxhttps://www.hobbycraft.co.uk/kraft-card-12-x-12-inches-20-sheets/645580-1000Strong card leading on from the paper walletsThere are bitumen sandwiched by a layer of card on each side, which is quite strong due to the paper and waterproof due to the bitumen.Tyvek Walletshttps://mightywallet.shop/blogs/news/make-your-own-paper-wallet-tutorialStarted making wallets from one tyvek envelope as a DIY project without having to sew anything together and was easily customisable as users can just draw on their wallet.A polyester based material used for wrapping houses to keep the moisture outCould be an offcut based product, using scraps from construction sites to produce wallets as and when they have enough material.Plenty of scraps in skips.Tyvek Sewinghttps://backpackinglight.com/forums/topic/2491/Main outcomes of this were sewing details which are covered on the hand written A3 sheetOrigami bookFolding Techniques for Designers: From Sheet to Form – Book by Paul JacksonResearch regarding types of fold to create the tool pockets was essential and this book helped me focus in on certain types of folds. The final fold concept was the knife pleat which I adapted to be a pocket.Draft Supply Chain

Cut Layouts

Image linksSkip –http://www.constructionphotography.com/ImageThumbs/A088-01006/3/A088-01006_Overloaded_skip_on_a_building_site__waste_segregation.jpgWallet –https://cdn.shopify.com/s/files/1/2061/9599/products/DY-400_Airmail_2_1024x1024.jpg?v=1570216030Messy Tools –https://www.gregschwem.com/wp/wp-content/uploads/2017/12/messy-tool-chest.jpgToolroll –https://www.picclickimg.com/d/l400/pict/183335665819_/Antique-Auger-Bits-In-Tool-Roll-Job.jpgOrigami –https://live.staticflickr.com/8112/8523219867_f88305bfa4_b.jpg

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