The Next Evolution in Packaging 3D Printing Next Evolution in Packaging 3D Printing Isabelle Xu APAC...

The Next Evolution in Packaging 3D Printing

Isabelle Xu APAC Category Lead, Packaging Associated British Foods plc, Shanghai, China Isabelle.Xu@abfchina.com

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 Isabelle.Xu@abfchina.com