Rethinking the packaging design workflow with 3D printing
In today's market environment, packaging is not only a support and protection, but also a key element of the brand experience: it should be easy to use, visually appealing and sustainable. With this focus, we now present an exciting example: one of the redesigns of PepsiCo Beverages North America's 2-liter bottle.
PepsiCo’s goal was to create a 2-liter bottle that was more ergonomic, more branded, and more user-friendly. The design and development team took a human-centered approach, studying how consumers use bottles: how they hold them, how they pour, and what movements they make. The process involved thousands of sketches and more than a hundred 3D prototypes.
The old process: compromises at every step
The classic packaging development workflow looks like this:
– industrial designers sketch concepts;
– engineers rework them into something that can be manufactured;
– some early, “white”, low-detail 3D print is made;
– and later, at an external supplier, the first truly tangible, colorful, translucent, near-final sample is made using traditional tooling.
And all this takes a lot of time.
PepsiCo's structural packaging design and R&D team completely redesigned the process based on Stratasys PolyJet technology.
What does this mean in practice?
PepsiCo’s engineering team can also use the J55 printer to produce short-run blow mold tooling, which is significantly faster than having a traditional metal tool made. This is critical because it allows the bottle shape to be tested in a production environment.
The team creates a full-color, Pantone-validated model with clear windows and graphics in-house in a matter of hours. So it’s not a “white blank,” but a bottle or packaging sample that can be easily photographed for POS material or placed in a shelf simulation.
According to Max Rodriguez, senior manager of R&D at PepsiCo Global Packaging & Engineering, being able to produce a tool or aesthetic prototype within 24 hours without involving an external supplier is a huge time saver.
In the food and beverage industry (and fast-moving consumer goods in general), time is money. Any tool that shortens the iteration cycle is a competitive advantage.
PepsiCo is very conscious of this.
In addition to time, cost is also a critical factor. With the inclusion of additive manufacturing technology, we are not talking about a theoretical advantage, but about concrete, measurable savings. In PepsiCo's experience, a traditional, custom tool typically costs $5,000 to $10,000 depending on the complexity of the shape, while with the Stratasys J55, they were able to reduce the same cost to under $1,000.
