It's a well-known fact that 3D printing is being used in a wide variety of industries for prototyping, creating functional jigs and fixtures, and even for creating end-use parts and products. This article will showcase how in-house 3D printing can benefit commercial product design and automated packaging by saving time and money, and preventing unexpected delays in production.  

1. Faster Visual Prototypes for Your Products

Instead of relying on digital renderings, having a tangible prototype can help in product design and considerations. By using a 3D printer, you can save time and money creating product mock-ups when compared to traditional methods. 

Example: Drink Can Designs

Dual extrusion 3D printers like the Ultimaker S5 make it very easy to communicate color differences in visual prototypes. 

Conventional Method: 

  • Material: Aluminum and Ink
  • Lead time: 2 weeks
  • Cost: ~$150

Using 3D Printing: 

  • Material: PLA Filament
  • Lead time: 24 hours
  • Cost: ~$10 - 93% cost savings

Drink can design - photo courtesy of Ultimaker
Drink can design - photo courtesy of Ultimaker

2. Create Functional Prototypes of Products

Iterate on designs quickly and even 3D print in materials that your end-product will be made from for accurate testing. 

Example: Squeeze Tubes

This fast, single-wall print is made from Polypropylene filament, a commonly-used material in the packaging industry, and a working hinged cap from Tough PLA.

Conventional Method: 

  • Material: Foam/CNC
  • Lead Time: 2 weeks
  • Cost: ~$130

Using 3D Printing: 

  • Material: Polypropylene and Tough PLA
  • Lead Time: 4 Hours
  • Cost: ~$3 - 98% cost saving
Squeeze Tube 3D printed prototypes
Squeeze Tube 3D printed prototypes

3. Create Assembly and Support Tools

Customizable assembly and support tools can not only be more efficient for specific jobs and parts, but they can be safer as they are designed specifically for the job at hand. 

Example: Ergonomic Wrench

This wrench has ergonomic enhancements that are highly beneficial for the user. This type of customization can happen quickly thanks to 3D printing. 

Conventional Method: 

  • Material: stainless steel
  • Lead Time: 2 weeks
  • Cost: ~$600

Using 3D Printing

Customizable 3D printed ergonomic wrench
Customizable 3D printed ergonomic wrench

4. Create Quality Control Tools

3D printing is the ultimate customization tool, allowing you to create exact jigs and fixtures needed during product production to ensure that all your products are made exactly the same.  

Example: Label Gauge 

This low-cost solution ensures that labels are positioned correctly on product packaging. 3D printing gives you the freedom to create this kind of tooling easily.

Conventional Method: 

  • Material: metal or POM
  • Lead Time:  week
  • Cost: ~$130

Using 3D Printing

  • Material: PLA Filament
  • Print Time: 7 hours
  • Cost: ~$1.50 - 99% cost saving
Custom 3D printed Label Gauge
Custom 3D printed Label Gauge

5. Replace Equipment Parts Quickly

Breaks happen. When something breaks on the production line, you can quickly and easily 3D print a custom part to replace the broken one, and even print spares to have on standby.  

Example: Sprocket Wheel

One of the most common 3D printing applications used in production facilities is replacing spare parts quickly. This Sprocket Wheel is printed in a self-lubricating polymer, which can withstand the wear and tear of the production environment. 

Conventional Method: 

  • Material: PA6/66
  • Lead Time: 3 weeks
  • Cost: ~$30 (MOQ 20)

Using 3D Printing

Easily create replacement parts for equipment.
Easily create replacement parts for equipment.

Have more questions about how 3D printing can help you develop products? Email sales@matterhackers.com to learn more.