one- and two-piece prototype in
Accura ClearVue, a rigid and tough
clear 3D plastic material offering the
highest clarity and transparency on
the market.
PROTOTYPING FUNCTIONAL AND
AESTHETIC PACKAGING
In just four days, the SLA prototypes
were printed and finished to meet
Birdstone’s quality and realism
requirements. 3D Systems’ experts
followed the premium finishing
protocol for Accura ClearVue to
deliver water-clear prototypes
through a process of wet and dry
sanding followed by clear coating.
These prototypes were then
submitted for manufacturing
tests and consumer research to
validate and rate the success of
each concept, and to assess the
performance and limitations of each
packaging option at all critical touch
points.
At this stage, Birdstone ordered four
copies of the leading packaging
design from 3D Systems On
Demand Manufacturing, which were
created using 3D Systems’ cast
urethane process. The preferred
SLA prototype was used to make a
mould which was then used to cast
additional water-clear copies using
polyurethane, a material very close
to what would be used for the final
product.
ARRIVING AT THE FINAL DESIGN
Following full evaluation of the
clear prototypes, the final design
was officially selected: an attractive
one-piece clamshell case, uniquely
www.engineeringnews.co.nz 19
instability due to the light weight of
the product and the properties of the
tray material.
Birdstone knew that arriving at
the correct design would require
accurate prototypes, and therefore
reached out to 3D Systems and its
On Demand Manufacturing due to
previous successful collaborations.
COLLABORATING TO DELIVER
FUNCTIONALITY AND BUILD BRAND
EQUITY
Birdstone worked closely with
Carman’s marketing and product
development teams as well as
its packaging supplier to review
and narrow the packaging design
concepts to two.
From the outset, the top priority was
to maintain supply chain efficiency
throughout packaging manufacturing
and product filling, followed closely
by building brand equity into the
tray with an effective and hassle-free
customer experience. Relaying
this information to 3D Systems On
Demand Manufacturing, Birdstone
and the 3D printing service bureau
talked about the requirements for
the prototypes.
Due to the complexity of the casing
designs and unique functional
requirements involved, 3D Systems’
On Demand Manufacturing experts
helped Birdstone select the most
suitable prototyping process,
materials, and finishing process to
meet its outlined requirements.
Using stereolithography (SLA) 3D
printing on 3D Systems ProX 800
machine, 3D Systems built both a
CHALLENGE:
Accurately prototype functional clear
packaging design to select the best
option for a new product launch.
SOLUTION:
Clear 3D printing by 3D Systems’ On
Demand Manufacturing experts using
Accura ClearVue SLA printing with
additional copies created using cast
urethane.
RESULTS:
• Accurate quoting kept project cost
within budget
• SLA prototypes ready in four days
• Accura ClearVue and 3D Systems’ cast
urethane process deliver water-clear
parts
• Functional and aesthetic prototype
features enabled effective manufacturing
tests and consumer research
contoured to the shape of the
stacked biscuits.
According to Grant Davies, director,
design & strategy at Birdstone, “The
final design plays to the strengths of
the packaging material and provides
a secure, re-useable home for the
crackers throughout the supply
chain and into the customers’
hands. It is functional enough to
be filled, stylish enough to serve
from, and securely re-closeable for
on-the-go snacking.”
Birdstone says that by adding
another level of consumer
engagement through functional
and aesthetic packaging, Carman’s
is able to offer a deeper brand
experience beyond consumption.
Carman’s exciting range of crackers
has forged a new place in the
market for the company, and the
tray has earned it many fans through
the cleverness and convenience of
its design.
Birdstone says it is delighted to have
contributed to a successful final
product for its client, and to answer
the unique challenges of the project
within a tight deadline.
“As usual, 3D Systems On Demand
Manufacturing was a wonderful
partner and worked with us to
provide the most effective and
appealing concept prototypes within
the project budget,” says Mr Davies.
Birdstone’s packaging insert for
Carman’s Super Seed & Grain
Crackers was a 2018 finalist in the
Packaging & Processing Innovation
& Design Awards.
for storage. For ease of access, it
was determined that the crackers
should be stacked in three columns
with room to encase the top
crackers without crushing them, but
also be easy to fill to not disrupt the
production line.
Lastly, the packaging needed to
meet the retailer requirement for
vertical packaging to maximise
differentiation on the shelves. There
was also a question of on-shelf
/www.engineeringnews.co.nz