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The Next Evolution in Packaging 3D Printing
Isabelle Xu APAC Category Lead, Packaging Associated British Foods plc, Shanghai, China [email protected]
PACE Asia, 4-5 Nov. 2015, Singapore
Corporate Overview of ABF plc
• Diversified international food, ingredients and
retail group
• 118,000 employees
• Presence in 47 countries
• Turnover £ 12.9 billion in 2014
• No. 4 largest Food Company in Europe
• Listed on London Stock Exchange
Sugar Ingredients Grocery Retail Agriculture
ABF Leading Brands
Agenda: • 3D Printing Concept
• 3D Printing Application on Packaging
1. Application on Packaging Development
2. Application on Production Line Validation
3. Application on Mass Production
• Different 3D Printing Technologies Applicable on
Packaging
• 3D Printing Reference Customers & Suppliers
3D Printing Application on Packaging
Definition
It is a process of joining materials to make objects from 3D
model data.
Process
Lay successive layers of material down under computer
control.
Materials
Plastic, Metal, Ceramic, and other materials.
What is 3D Printing?
Cost Efficiency
Quality Innovation
3D Printing Application on Packaging
3D Printing Application on Packaging
Production Line
Validation
Mass Production
Packaging Development
Technology: SLS, SLM, SLA, FDM, Polyjet, etc.
Polyjet provides Color and Multi-Material 3D Printing
• Digital Manufacturing • High feasibility and adaptability • CAD model driven • Fast and various material
3D Printing Application on Packaging
Idea
CAD Design
3D Print
Optimization
Evaluation
Manufacturing
Source: Stratasys
.
Source: Stratasys, ABF
Case Study-Rapid Prototyping (RP)
SLS
SLA
SLS
Polyjet
SLS
Polyjet
Cap orifice size and design
Dosage requirement
Formula viscosity
Formula surface
intension
Case Study- Rapid Prototyping (RP)
Source: Stratasys
Function Improvement
Solution: Make 7 different orifice design prototypes
Source: Stratasys
Technology Cost (USD)
Development time
Unit Cav. tooling (7 sets)
50,000 1-2 months
3D Printing 3,000 24 hours
Case Study- Rapid Prototyping (RP)
Product: Sun Care Lotion
Problem: Liquid dripping due to low surface intension
PolyJet
Increase Creativity
Speed to the market
Minimize the R&D Cost
Increase the efficiency
Maintain Confidentiality
in-house
What do 3D Printing bring us?
Source: Stratasys
3D Printing Application on Packaging
3D Printing Application on Packaging
Application:
• Produce hundreds of
samples for
• Line trail Filling
• Line Testing
• It also can produce
Puck/Jig to be used in the
production line
Production Line
Validation
Mass Production
Packaging Development
PolyJet mold on blow molding machine PolyJet mold with polyethylene bottle
Application-Blow bottle
Filling Line Design and Testing
Technology Cost (USD) Development time
Aluminum mold 8,000 1 month
Polyjet mold 1,600 24 hours
Source: Stratasys
PlolyJet Mold
A three-part mold was built with Digital ABS, assembled onto an aluminum frame base. The mold create more than 300 test samples with nearly production appearance
Production Line
Validation
Mass Production
Packaging Development
3D Printing Application on Packaging
Advantages:
• Fast
• Effective
• Cost reduction
Mold Closing
Injection time
Holding Pressure
phase
Cooling phase
Mold opening
Source: EOS
Injection mold cycle diagram
Application- Injection Molding
The cooling time takes around 70% of the total molding time.
Application- Injection Molding
Objective: Cycle time reduction by conformal Cooling
Conventional Cooling Channel
3D Printing
Conformal Cooling Channel
(CCC)
Source: EOS
Application- Injection Molding
Source: EOS
For products with complex geometry In order to remove heat from areas where conventional tooling method can not reach, 3D printing technology (DMLS) is usually applied.
Almost unlimited freedom of design
Critical areas can be reached due to CCC
When to use DMLS?
Conventional mold fabrication process has 2 constraints: 1.No cooling channel can be designed in yellow area. 2.The cooling channel has to be far from the part. Objective: to reduce 20% cycle time
Jar in the mold
Case Study- Conformal Cooling
Conventional Cooling Channel
3D Printing
Conformal Cooling Channel (CCC)
3D printed based on a conventional steel base
3D printed conformal cooling channel curves and closely follow the geometry of the part
CCC
Conventional tool
PP Jar (USD0.05/pc)
Mold core temperature is reduced from 35°to 22° Mold cooling time is reduced from 11.1s to 6s, 45% reduction
Mold cycle time is reduced by 34% Daily output is increased by 30% Efficiency is increased by 60% Saving: USD 80,000 based on annual volume of 10MM pcs
Case Study- Conformal Cooling
Conventional Cooling
Conformal Cooling 3.5s 6s 8.9s
5.7s 11.1 s 11.1s
Injection & holding Cooling time
Mold opening & part injection Mold Cycle Time
27.9s
18.4s
Eight 3D printed cores Eight 3D printed cores
Problem High wastage , 50% due to the clarity issue and injection point warping
Case Study-Improve Quality
PETG Jar (USD1.5/pc) Result – Eliminate burning defects and warping on the
injection point
– Improve the clarity of the jar
The wastage is reduced from 50% to 25%
The cycle time is reduced by 7%.
Saving:USD140,000 based on annual volume of 500,000 pcs
Source: HCP, YB
Problem High wastage , 50% due to the clarity issue and injection point warping
PETG Jar (USD1.5/pc) Result – Eliminate burning defects and warping on the
injection point
– Improve the clarity of the jar
The wastage is reduced from 50% to 25%
The cycle time is reduced by 7%.
Saving:USD140,000 based on annual volume of 500,000 pcs
Problem – Sink mark in the jar bottom and the wall
– Slugged bottom
– Wiredrawing in the injection gate
Case Study-Improve Quality
PETG Jar (USD2/pc) (Twice injection) The bottom thickness:10mm
The wall thickness: 6-12mm
Result – No wiredrawing and shrinkage
– Higher Clarity
– Smoother in the bottom
– One time injection
The wastage is reduced from 40% to 15%
The cycle time is reduced by 6%.
Saving:USD160,000 based on annual volume of 500,000 pcs
Source: YB
WARPAGE
STICKY MOULD MUDDY WIREDRAWING
Quality problems could be solved
Source: YB
Sustainability
Energy saving in injection moulding
process
Shorter Payback
time
Breakeven Scrap rate reduction
Plastic material saving
Further optimization
possible
Manufacturing chain
Project definition and requirements
Tooling inserts CC
design
Simulation
Insert manufacturing
Finishing& post
processing
Mould assembly & mould proving
Injection moulding process
DMLS manufacturing
chain
Source: EOS
Manufacturing of sustainable parts with the DMLS manufacturing chain
Case Study- Conformal Cooling
Stereo Lithography (SLA) 立体光固化成型法 Applicable material：photopolymer光硬化树脂 Machine Maker: 3D Systems
Different Types of Technology
Source: 3dprintingindustry, solidconcepts, 3delement
SLA
Selective Laser Sintering (SLS) 选择性粉末烧结系统 Applicable Material：thermoplastic热塑性塑料 Machine maker：EOS, 3D Systems
Different Types of Technology
•Source: wikipedia
SLS
SLS
Fused Deposition Modeling (FDM) 熔融层积成型 Applicable material：themoplastic (热塑性塑料) Machine Maker: - Stratasys
Different Types of Technology
•Source: uni.edu
FDM
Paper Tray mold
Thermoforming Tray Mold
Selective Laser Melting (SLM), DMLS选择性激光熔融 Applicable materials：almost all kinds of alloy Machine maker： -EOS -Concept Laser -SLM -Renishaw
Different Types of Technology
•Source: custompartnet
PolyJet
Polyjet
PolyJet mold on blow molding machine
PolyJet mold with polyethylene bottle
Different Types of Technology
PolyJet
Applicable：UV cured resin光敏树脂 Machine maker： - Polyjet (Stratasys)
Polyjet
New Era of Innovation Production
3D Printing FMCG Users
Famous 3D Printing Suppliers
Isabelle Xu APAC Category Lead, Packaging Associated British Foods plc, Shanghai, China [email protected]