Advantages of 3D printing in automated packaging

With 3D printing technology becoming more reliable and accurate, more and more production lines are taking advantage of its unique advantages to reduce manufacturing time, increase flexibility, lower costs and speed up delivery. One of the key industries in which the implementation of 3D printing is starting to show its potential is the packaging industry . While each topic can be explored in detail here, the goal is to provide a comprehensive overview of the main benefits.

Cost reduction

One of the ways that 3D printing reduces costs in packaging is through the reduction of prototyping costs. Traditional prototyping often requires time-consuming injection molding setups or mold casting expertise, while 3D printing enables the rapid creation of iterative designs that can be refined overnight.

Whether it is custom templates or specific parts for conveyor systems – as is the case with our client Krones – the ability to produce parts without the need for tooling specialists reduces labor costs, while Print Process Reporting provides detailed post-press reports to validate parts before they are deployed. This brings savings in the short term (through reduction of material waste) and in the long term (reduction of the need for skilled labor).

3D printing enables localized production closer to the end user. Manufacturing and shipping replacement parts for maintenance, especially over long distances, is expensive and inefficient when the goal is to maintain optimal production uptime. The availability of 3D printers, such as Factor 4 , in local packaging facilities enables the production of replacement parts on demand, with minimal material waste and without the need for a high level of customer expertise.

In addition to localized manufacturing, the ability to adaptively 3D print lightweight modular parts for production lines enables faster changeovers between different packaging formats, reducing machine downtime and labor costs. For example, switching from an inverter for packaging 3.6oz ice cream cups to a 16oz package can be done much faster with the help of 3D printed parts.

Simplification of material components

While it is often emphasized that additive manufacturing uses only as much material as is needed, its ability to consolidate multi-part assemblies is often overlooked.

Packaging inserts , one of the most commonly used elements in packaging production lines, are traditionally made from different materials (foam, plastic, cardboard, etc.), with each material being cut, shaped and assembled separately. 3D printing enables the consolidation of the package insert into a single solution, reducing the need for different materials, assembly steps, machinery and manpower. This further contributes to reducing the carbon footprint, thanks to the use of durable, biodegradable filaments like PLA , and significantly reduces material waste.

This approach also enables the integration of existing solutions for the packaging of products of non-standard shapes. For example, in the production of limited edition glass bottles, which often have unique and irregular shapes, custom foam inserts are used to preserve the integrity of the design during transport. 3D printed inserts reduce the need for additional pads or spacers and allow production lines to use existing storage and transport systems, such as 24x33cl beverage crates.

The process from start to finish and the required knowledge

Returning to traditional manufacturing and packaging techniques, it is increasingly clear how 3D printing can improve the entire process from start to finish . It reduces the dependency on or completely eliminates the need for experienced engineers and designers who are necessary to create and operate complex tools and molds. These traditional processes often require specialized software, which further increases costs and requires technical expertise.

With 3D printing, the design process becomes more accessible thanks to a wide range of CAD software , some of which have a lower learning curve. A key advantage is the ability to directly translate a CAD design into a 3D printed prototype. When researching packaging options for new products, multiple design iterations can be produced overnight, instead of days or even weeks.

In practice, a designer with basic CAD knowledge can go from concept to physical prototype faster than using any traditional method.

Flexibility

It all boils down to the key advantage of 3D printers in packaging production – flexibility .

Whether it's adapting packaging lines to different sizes and shapes without the need for re-tooling, advancing traditional mold making for custom packaging through rapid iterations as needed, creating holders for packaging lines, or rapid prototyping to test packaging designs, 3D printing enables the design and implementation of a variety of solutions at far lower costs, less time, and less downtime than traditional packaging processes.

If you are thinking about how you could apply the benefits of additive manufacturing in your business model, feel free to contact us – our team of experts will be happy to help you!