Low-Volume Blow Molding with 3D Printed Molds
News • Formlabs
Save 70% of your time and 90% of the costs with 3D printing.
In the fast-paced world of consumer goods, speed and efficiency are crucial. Companies like Unilever are constantly seeking innovative solutions to stay ahead of the competition. One groundbreaking approach is the integration of 3D printed molds in low-volume rapid stretch blow molding (SBM). This method significantly reduces lead times and costs, making it an attractive option for prototyping and pilot production. With the advent of advanced 3D printing technologies, the manufacturing landscape is rapidly evolving, enabling businesses to innovate faster and more efficiently than ever before.
Rigid 10K
Rigid 10K Resin is the choice for professionals seeking exceptional strength, stiffness, and thermal resistance in their 3D-printed molds. Ideal for applications like stretch blow molding, this industrial material offers unmatched precision and durability, even under extreme conditions. Whether you need to capture complex details or ensure reliable production cycles, Rigid 10K Resin delivers impressive results. Ready to take your production to the next level? Click the link below to learn more and order now.
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The traditional process
Traditionally, the development and testing of new bottle designs involve several time-consuming steps. The process typically includes designing the mold, machining it from metal, and testing it on a production line. This workflow can take anywhere from six to twelve weeks and incur costs ranging from $2,500 to $100,000 per mold. Such timelines and expenses make it challenging to quickly iterate and adapt to market demands. The lengthy process not only delays time to market but also increases the risk of sunk costs if the initial design needs modifications.
The conventional process involves multiple stages:
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Design Phase: Engineers create detailed CAD models of the bottle and mold, a process that can take several weeks depending on the complexity of the design.
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Machining Phase: The CAD models are then sent to machine shops where the molds are cut from metal. This step involves several weeks of work, including setup time, machining, and manual finishing to ensure the molds meet exact specifications.
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Testing Phase: Once the molds are complete, they are installed on production lines for testing. This phase involves trial runs to ensure the molds produce bottles that meet all quality standards. Any issues discovered during this phase can result in further delays as the molds need to be adjusted or completely remade.
The benefits of 3D printed molds
3D printing offers a revolutionary alternative to traditional metal molds. With the ability to rapidly produce molds in-house, companies can cut lead times from weeks to days and reduce costs by up to 90%. This flexibility allows for quick iterations and multiple design tests simultaneously, which is essential for fast-moving industries. The use of 3D printed molds eliminates the need for extensive setup and machining processes, enabling designers to move from concept to physical prototype much faster.
Key advantages of 3D printed molds include:
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Speed: Rapid production of molds allows for quick turnaround times, enabling faster product development cycles.
- Cost Efficiency: Significant cost savings on mold production compared to traditional metal molds.
- Design Flexibility: The ability to quickly modify designs and produce multiple iterations without incurring high costs.
- Reduced Waste: Less material waste as 3D printing uses only the necessary amount of material for each mold.
Unilever and Serioplast
Unilever, in collaboration with Serioplast, has successfully implemented 3D printed molds for low-volume SBM. This partnership has resulted in significant time and cost savings, enabling them to bring products to market faster and more efficiently. By using Formlabs’ SLA printers and Rigid 10K Resin, they have achieved high precision and durability in their molds, suitable for hundreds of production cycles.
Key Findings
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Speed and Efficiency: The use of 3D printed molds has reduced pilot testing lead times from six to two weeks. This acceleration allows for faster product iterations and quicker responses to market demands.
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Cost Reduction: The cost of producing a 3D printed mold ranges from $500 to $1,000, a stark contrast to the $2,500 to $10,000 required for traditional metal molds. This drastic reduction in cost makes it feasible to test multiple designs without the financial burden.
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Quality and Precision: Rigid 10K Resin provides high strength, stiffness, and thermal resistance, ensuring that the molds can withstand the pressures and temperatures of the SBM process. This results in high-quality, production-like prototypes suitable for consumer testing and process validation.
Process Overview
The process of using 3D printed molds in SBM involves several steps:
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Designing the Mold: The mold design is optimized for 3D printing, considering factors such as thickness, support placement, and orientation during printing. Designers use CAD software to create detailed models, which are then prepared for printing.
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3D Printing: The mold is printed using SLA technology, which provides a smooth surface finish and high precision. SLA printing is preferred for its ability to produce intricate details and a high-quality finish, which are crucial for the molding process.
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Post-Processing: After printing, the mold undergoes washing, drying, and post-curing to achieve the desired properties. Post-processing steps are essential to enhance the mold’s strength and thermal resistance.
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Assembly and Testing: The printed mold is assembled into a metal frame and tested on an industrial SBM machine. This setup allows for the quick changeover of molds and efficient pilot testing. The assembled mold is then used to produce prototype bottles, which are evaluated for quality and performance.
Results and Applications
The bottles produced using 3D printed molds have shown comparable quality to those produced with traditional metal molds. They are suitable for various testing phases, including consumer testing, process validation, and line testing. This approach has enabled Unilever and Serioplast to produce about 200 units of each design within a month, a feat that would be economically unfeasible with traditional methods.
Applications of 3D Printed Molds:
- Consumer Testing: High-quality prototypes can be produced quickly for consumer feedback, allowing companies to make informed decisions about design changes.
- Process Validation: The prototypes are used to validate the SBM process, ensuring that the molds can handle production conditions.
- Line Testing: The prototypes help test the production line, including filling, capping, and packaging processes, to identify any potential issues before full-scale production.
The Power of Formlabs Form 4 and Form 3L Printers
Integrating Formlabs’ Form 4 and Form 3L printers into the stretch blow molding process offers significant advantages for factories and design companies. These printers provide high precision, rapid production, and cost-effective solutions, drastically reducing lead times and material costs. The Form 3L’s large build volume and the Form 4’s fine detail capabilities enable the production of high-quality molds and prototypes, allowing for faster iterations and innovative designs. By adopting these advanced 3D printing tools, businesses can streamline their workflows, accelerate time to market, and stay competitive in the fast-paced consumer goods industry.
Form 4 Printer:
- High Precision: Capable of producing parts with intricate details and smooth surfaces.
- Speed and Efficiency: Rapid printing processes reduce lead times, enabling quicker iterations.
- User-Friendly Interface: Easy to set up and manage print jobs, making it accessible for operators.
Form 3L Printer:
- Large Build Volume: Ideal for producing larger molds or multiple smaller parts in a single print run.
- Industrial-Grade Materials: Supports a wide range of engineering resins, including Rigid 10K Resin.
- Precision and Detail: Ensures high-quality production with fine details and accurate dimensions.
Lay3rs: Your Ideal Partner for Formlabs and 3D Printing Projects
When it comes to implementing advanced 3D printing solutions like Formlabs’ Form 4 and Form 3L printers, Lay3rs stands out as the best partner for your projects. With extensive experience and expertise in the field of 3D printing, Lay3rs provides comprehensive support from initial consultation to final implementation. Their team of professionals is dedicated to helping businesses harness the full potential of 3D printing technology, ensuring seamless integration into existing workflows and maximizing the benefits of rapid prototyping and production.
Lay3rs offers tailored solutions to meet the specific needs of each client, backed by exceptional customer service and technical support. Whether you are looking to enhance your prototyping capabilities, reduce production costs, or accelerate your time to market, Lay3rs has the knowledge and resources to help you achieve your goals. Trust Lay3rs to guide you through the adoption of Formlabs printers and other 3D printing technologies, making your transition smooth and your projects successful.
Dive deeper
Do you want to read more about this case study, or do you want to know how to start with the 3D printing of blow molds using Formlabs Rigid 10K yourself? Then continue reading!
The next step
Ready to revolutionize your prototyping and production processes with advanced 3D printing solutions? Partner with Lay3rs to integrate Formlabs’ Form 4 and Form 3L printers into your workflow, and experience the benefits of rapid, cost-effective, and high-quality production. Contact Lay3rs today to learn more about these cutting-edge printers, explore the possibilities of 3D printing blow molds, and receive a personalized offer. Our team is eager to assist you in transforming your ideas into reality. Reach out to Lay3rs now and take the first step towards enhancing your manufacturing capabilities.
