Additive manufacturing in the packaging sector

Additive manufacturing, or 3D printing, has established itself as a disruptive technology in several industries. Its application in the packaging sector is marking a turning point in the way packaging is designed and manufactured.

Traditionally, packaging has relied on conventional manufacturing methods, which require expensive molds, long production times and limitations in terms of design customization. With the advent of 3D printing, these barriers are disappearing, as this technology enables the rapid creation of customized parts and prototypes without the need for molds.

Specifically, additive manufacturing enables the rapid production of customized parts, tooling and prototypes, driving a constant evolution of the manufacturing process. In addition, this technology facilitates the creation of more complex and customized designs that are not possible with traditional manufacturing techniques.

In short, 3D printing is redefining the future of packaging, helping to overcome challenges such as reduced production times, cost optimization and the ability to adapt to increasingly complex and customized designs.

3D printing applications in the packaging industry

3D printing has changed the way parts and tooling used in packaging production lines are produced. It has also optimized the in-house production of critical components, reducing dependence on external suppliers and reducing lead times. Some key application examples include:

• Wear parts: These parts, which are often designed specifically for each machine and require frequent replacements due to heavy use, can now be produced quickly and accurately in-house. This not only reduces machine downtime, but also the costs associated with purchasing and delivery from external suppliers.
• Sprockets or star wheels: These elements can be custom-designed and manufactured using 3D printing, allowing a higher level of customization. In addition, the design can be quickly adjusted to accommodate changes in production, improving accuracy and efficiency in product transport.
• Format-specific parts: : 3D printing facilitates the creation of product-specific parts in unique shapes and sizes. This is particularly useful when handling multiple product formats on the same production line, as it allows for quick adaptation without the need for long lead times for specialized parts.
• Displacement inverter tunnels: Used to reorient products that are not positioned correctly, these 3D printed tunnels ensure that the packaging process is efficient, and that products arrive at their final destination in the right orientation, reducing errors and waste on the production line.
• Safety tools (LOTO): These tools can be custom-made with 3D printing, adapting perfectly to the specific machines and formats of the production line. This ensures that operations are performed safely and minimizes occupational hazards.
• Ergonomic measurements: Custom 3D printed tools and grips can be ergonomically designed to improve operator comfort. By providing tools that specifically fit the needs and capabilities of workers, fatigue and injuries can be reduced, which in turn improves productivity in the work environment.

Benefits of using additive manufacturing in automated packaging:

1. Optimization of operations

3D printing significantly reduces lead times, allowing parts to be produced in a matter of hours, even in remote locations.

2. Production flexibility

Parts can be produced quickly, reducing production line downtime and facilitating changeovers.

3. Reduced time to market

Companies can bring products to market faster due to the ability to produce prototypes and tooling efficiently.

4. Improved warehouse management

On-site manufacturing of parts reduces the need to stock large quantities of spare parts.

5. Safer worker environment

3D printed tools can be specifically designed to improve operator safety.

6. Increased overall efficiency

3D printing enables the creation of lightweight, robust and optimized parts, which improve the performance of packaging systems.

Success story in the sector

A notable example in the packaging industry is the company Morillas Brand, who trusted us to achieve their goal of optimizing their production of customized parts and packaging tools.

Thanks to the integration of a 3D printing equipment, they have managed to reduce both production times and costs, as well as increase flexibility in their packaging lines. This has enabled them to adapt nimbly to changing market demands.