3D Printing in Packaging Machine Manufacturing: Faster, More Flexible, More Customised

Additive manufacturing not only accelerates the development of packaging machines, but also enables customised, rapidly available components – from prototypes to digital spare parts. How 3D printing is changing mechanical engineering.

An employee checks the printing progress of a component in front of a 3D printer. — Additive manufacturing is reshaping the design, production, and maintenance of packaging machinery.

Whether fast prototypes, customised grippers or sustainable spare parts – 3D printing brings speed, flexibility and customisation to the development and production of packaging machines. The technology really comes into its own with complex geometries or small batch sizes. What used to take weeks is now often a matter of hours. No wonder, then, that specialised service providers, machine builders and brand manufacturers alike are turning to additive manufacturing. ‘Prototypes can be produced much faster, and the transition to series production is also quicker because no complex set-up processes are required. A 3D printer can flexibly produce different geometries – ideal for changing formats and smaller quantities,’ sums up Melina Bluhm from 3D printing specialist Replique.

Part of a packaging machine produced in a 3D printer — UltiMaker’s PET CF starwheels, inspired by Krones, improve bottle handling in tough production settings.

Andy Middleton, SVP EMEA at UltiMaker, a Dutch manufacturer of 3D printers, adds: “Manufacturers of packaging machines are generally looking for 3D printing solutions that offer durability, precision and speed.” This is because the printed components have to withstand extreme stresses – such as heat, pressure or constant mechanical stress – while maintaining tight tolerances. High-performance materials with distinctive mechanical properties are therefore usually used for functional applications: they combine high strength, flexibility, stability and resistance to wear.

With regard to applications, the focus in packaging machine manufacturing is primarily on format parts – i.e. components that change regularly depending on the product and type of packaging. A key driver here is the ever-shorter product life cycle. Manufacturers are constantly bringing new products to market – and need new format parts just as quickly.

With the help of 3D printing, these can be quickly and flexibly adapted to new product formats – a decisive advantage in a dynamic market environment. “In addition, the technology enables innovative lightweight construction solutions and the integration of complex functions, for example through force-optimised design, integrated supply channels or spring-loaded structures,” says Stefan König, Managing Director/CEO at packaging machine manufacturer Optima.

According to Middleton, high-performance materials such as carbon fibre-reinforced nylon, PEEK or polycarbonate are suitable for particularly demanding applications. They offer excellent strength, wear resistance and dimensional stability – ideal for high-speed lines or automated handling systems.

Robot gripper is holding a packaging with food in a machine. — Schubert relies on 3D printing to quickly and flexibly adapt format parts to new product requirements.

3D Printing Improves Machine Availability

At Optima, 3D printing is now firmly established as a strategic tool. It is used in almost all machines and supports development, production and service in equal measure. “Even in the early concept phase, 3D-printed test parts enable rapid feasibility analyses – even before orders are received,” says Stefan König. The areas of application are diverse: gripping and suction tools, format parts, covers, reductions and feed units are additively manufactured, as are fixtures, setting gauges and tool holders for assembly. The company from Schwäbisch Hall also uses 3D-printed models for training purposes.

Manufacturers of consumer goods in particular benefit from additive manufacturing: thanks to their rapid availability, customised 3D format parts help to optimally adapt packaging systems to new products every few weeks.

“In highly competitive industries such as the food market or the cosmetics industry, it is important to react quickly to market changes. This is possible with 3D printing,” says Conrad Zanzinger, Technical Director at SchubertAdditive Solutions.

At machine manufacturer Harro Höfliger, 3D-printed components are sometimes used as a temporary solution until conventionally manufactured spare parts are available. “Some of our customers now have their own 3D printers so that they can manufacture spare parts themselves as needed, thereby increasing the availability of their equipment,” explains Stefan Traub, Department Leader Design & Development at Harro Höfliger.

Less Waste, More Process Reliability

Another major advantage of 3D printing is the possibility of customisation. “In addition to producing individual parts in variable geometries, assemblies can also be redesigned,” says Melina Bluhm. This is done, for example, by combining previously multi-part components into a single printed part. Or by using a modular design in which only individual elements need to be replaced, e.g. to respond to different packaging formats.

Conrad Zanzinger confirms: “Many consumer goods are difficult to package due to their shape. Conventional grippers in packaging machines are sometimes not optimally matched to the goods and may lose products during the packaging process.” This is not the case when the tools are perfectly matched to the food or cosmetic product thanks to 3D printing. Not only does the process in the machine run more safely, but there is also less waste because the products end up securely in the packaging and do not slip out of the tool’s grip.

In the service sector, additive manufacturing offers the possibility of producing spare parts worldwide on demand. This significantly reduces downtime and increases machine availability. Melina Bluhm therefore also sees a considerable customer advantage in the on-demand principle. Components no longer need to be physically stored in a warehouse but are stored in a digital warehouse, as in the case of Replique, and can be retrieved as needed – the moment the customer receives an order from an end customer. This enables efficient, demand-driven production. “We like to say that the most expensive spare part is the one that's missing,” says Melina Bluhm. This is exactly where digital spare parts models in combination with 3D printing come into play: production takes place via a global network – ideally locally at the end customer's site – and is delivered directly to them.

3D printing has thus long since established itself as a strategic tool in packaging machine manufacturing – not only in development, but throughout the entire life cycle of a machine. From quickly available format parts and customised grippers to digital spare parts warehouses, the technology offers versatile answers to the growing demands for speed, flexibility and efficiency. In a market that constantly demands new products and formats, additive manufacturing is thus becoming a key driver of innovation.

Author: Alexander Stark