Unilever, a global leader in fast-moving consumer goods (FMCG), has embarked on a groundbreaking collaboration with Serioplast Global Services to transform packaging prototyping using 3D printing technology. This innovative approach aims to accelerate product development cycles and significantly reduce costs associated with traditional mold-making processes.
Stefano Cademartiri, CAD & Prototyping Owner at Unilever, highlighted the imperative for swift market presence: “A consumer goods company like Unilever must be on the market as soon as possible or before your competitors. You need to offer the best product at the best price in the shortest time possible to the consumers. 3D printing helps us speed up this process.”
In this partnership, Unilever and Serioplast explored the feasibility of utilizing 3D printed molds for low-volume stretch blow molding (SBM) to streamline prototyping and pilot testing. By leveraging this technology, they managed to slash lead times by six weeks and reduce costs by up to 90%.
Traditionally, blow molding, a widely-used method for producing plastic products, demanded extensive lead times and incurred significant expenses. Metal tooling, essential for SBM, often took several weeks to produce and came with hefty price tags, constraining innovation and prolonging product development cycles.
However, with the adoption of 3D printing, Unilever and Serioplast have revolutionized this process. The use of Formlabs’ Stereolithography (SLA) 3D printing technology and Rigid 10K Resin material enabled the rapid fabrication of molds with intricate details and high precision. This approach not only accelerated prototyping but also facilitated realistic pre-production parts, closely resembling final products.
Flavio Migliarelli, R&D Design Manager at Serioplast Global Services, emphasized the transformative impact of this collaboration: “With the 3D printed mold, we can save up to 70% time and 90% cost compared to the standard mold. In the past, [clients] had to wait up to 12 weeks just for one design, now we can make five designs.”
The advantages of 3D printed molds extend beyond rapid prototyping. They enable Unilever to conduct extensive consumer testing with representative samples, ensuring products meet customer expectations before mass production. Additionally, these molds facilitate validation of the SBM process and preform suitability, as well as early testing of manufacturing line aspects, further streamlining production.
Reflecting on the collaboration, Cademartiri expressed gratitude for Formlabs’ support in this transformative journey: “In Formlabs, we found a very good partner not only for selling the machine but also for supporting us in discovering the properties of these materials.”
Ultimately, Unilever’s adoption of 3D printing for packaging prototyping heralds a new era of agility and efficiency in product development. By embracing innovative technologies, the company aims to bring superior products to market faster while mitigating risks and reducing costs associated with traditional mold-making processes.