Creating Realistic

Packaging Prototypes

with 3D Printing

Matthew Pray and Michael Storey

Managing Partners

Beckatt Solutions

November 5th, 2014

Overview of 3D Printing

• What is 3D printing?

• Materials

• Industry growth

Who is Using 3D Printing

• Industries

• Companies

• Consumers

Software

• CAD

• 3D Modeling Software

• SolidWorks, SpaceClaim, Inventor, etc.

$64,000 Question

Why use 3D Printing for Packaging?

Packaging Applications

Prototyping/Concept Modeling

• Ease of concept change• Tangible products to

present internally and Externally

• Design understanding• Time to market• Exceed customer

Expectations• Simulation of final

product• Visual selling capabilities

Additional Uses

• Molds for thermoform packaging

• Sleeve shrink visualization

Smart to Market

• Concept to sample

• Consumer perception

• Speed up your engineering productivity

• Cost savings (e.g., labor and materials)

• Bring multiple options to the table

• 3D is the wave of the future

• Win more sales!

Flexible Packaging

• Mcor Flex

• Living hinge capabilities

Paper-Based Printing

• Low cost of consumables

• Full color capabilities

• Eco-friendly

• Final product comparison

• Durability

• High resolution

Creating Realistic Packaging Prototypeswith 3D Printing Case Study

Unisource Engineered SolutionsWe build on our in-depth materials knowledge,

practical experience and strategicmanufacturing relationships to create packaging

solutions that add value to your product, help reduce total cost and strengthen your

competitive advantage.(Source: www.unisourceengineeredsolutions.com)

Unisource Engineered Solutions (UES)

• One of the largest independent distributors and marketers of 150,000+ national and private-label products in North America

• Division of Unisource Worldwide• Founded in 1968• Headquarters: Norcross, Georgia (with offices

worldwide) • Combine science and art to create high-impact

product packaging solutions• Committed to innovation and sustainability

Challenges

• Thin-walled packaging from bamboo pulp and sugar cane residue (Bagasse)

• Hollow packaging for each packaged part

• Plastic prototypes don’t resemble final packaging

• Customers could be confused when final product is not similar to prototype

• Sales can be derailed

Objectives

• Create more realistic prototypes

• Enhance customer understanding and satisfaction

• Increase sales

Strategy

• Design in SolidWorks3D CAD and ArtiosCADsoftware

• 3D print prototypes of molded pulps with paper in house

3D Printer Selection Criteria

• Paper build material

• Durable

• High-resolution

• Folding materials and boxes

Decision: Mcor Matrix 3D Printer

• Uses standard office paper

• Durable

• High-resolution

• Long-lasting living hinges

• Low material costs

• Fast, easy, safe, eco-friendly

• Proven success in another division

Results

“The

Matrix is

an

important

cog in

helping us

make the

sale and

delight the

customer.”

-UES

Results

“The Matrix is

an important

cog in

helping us

make the

sale and

delight the

customer.”

-UES

How It WorksSelective Deposition Lamination (SDL)

Height-adjustable Tungsten

carbide tip cuts the shape of the

prototype.

Water-based adhesive deposited

in tiny dimples, by precision

delivery system.

Mcor SliceIT digitally slices 3D design into layers matching thickness

of the paper.

Electronic slices sent to the printer one by one, similar to how a PC

sends pages of a standard document to a 2D printer.

Adhesive concentrated on the area inside

the model, while the unneeded material is

only very lightly held together, enabling fast

and easy prototype removal.

How It Works Selective Deposition Lamination (SDL)

Adhesive

First Sheet

Next Sheet

Press

Cut Repeat

How It Works Selective Deposition Lamination (SDL)

Load A4/letter

paper & adhesive

Setup build and remove part

Load Paper

Printer loads the next

sheet

3D printed object is

ready

Open 3D object in

SliceIT software Click “Print Model”

First layer is cut Adhesive applied & sheets

squeezed together

Remove build plate Pull away

surrounding paper

Results

• Durable paper prototypes closely simulate final packaging

• Customers understand designs from the start

• Customer expectations exceeded

• Customer satisfaction increased

• Win more sales

• Prototype costs cut (5% of plastic)

• Shortened time to market (1 week vs. months)

• Additional uses: molds for thermoform packaging and prototypes of products from which packaging is designed

• Green process and recyclable prototypes

• Innovative, world-class technology enhances perception of UES

Contact Beckatt Solutions

Matthew Pray

mpray@beckatt.com

630.206.3993 x 255

Michael Storey

mstorey@beckatt.com

630.206.3993 x 245

www.Beckatt.com

www.McorTechnologies.com