The Supply Chain Packaging Optimization team at Chainalytics presented "The Story of Mojo: Building a Packaging Focus into Product Design" at ISTA TransPack Forum 2014. Companies driven by innovation are most effective when stakeholder input is incorporated early and often. This is especially true when it comes to packaging engineering and supply chain management. Stratasys, a leading manufacturer of 3D printing equipment and materials, embraced this thinking when it partnered with Chainalytics, a global leader in packaging and supply chain consulting, to design its new 3D desktop printer, Mojo. To learn more on how to optimize your packaging or product design while keeping your supply chain needs and distribution requirements at the forefront of the project, contact our packaging optimization specialists at packaging@chainalytics.com or simply call +1 (612) 252-1830

1. The Story of Mojo:
Building a Packaging Focus
into Product Design
23 April 2014
PRESENTED BY
&

2. Agenda
2
Stratasys Overview
Introducing the Mojo 3D Printer
Product Design & Product Testing
Distribution Test Protocols
Packaging Design & Test Results
Final Configuration & Current Performance

3. About Stratasys
Stratasys manufactures professional 3D printing equipment
and materials that create physical objects directly from
digital data. Its systems range from affordable desktop 3D
printers to large, advanced 3D production systems, making
3D printing more accessible than ever.
Stratasys 3D printers are used to:
 Create models and prototypes for new product design and testing
 Build low volume finished goods
 Elevate research and learning in science, engineering, design, and
art
 Create gifts, novelties, customized devices, and inventions
3
Who is Stratasys?

4. Stratasys Desktop 3D Printing
 Stratasys’ Ideas Series is a line of professional desktop
3D printers
4
 uPrint
 Build envelope
 uPrint SE: 8” x 6” x 6”
 uPrint SE Plus: 8” x 8” x 6”
 Material bay: 25” x 26” x 31”;
168lbs
 Mojo
 Build envelope: 5” x 5” x 5”
 Material bay: 25” x 18” x 21”;
60lbs

5. Developing a New Printer Platform
 Almost entirely new technology
 Hundreds of engineering requirements:
 Performance
 Reliability
 Usability
 Shipping Mode
 Smaller than print envelope
of 900mc printer
(which is 36” x 24” x 36”)
5

6. Key Packaging Requirements for Mojo
 Ship in single package without pallet
 Design for 30g maximum impact shock
 Meet small parcel package requirements
 Maintain system performance post distribution cycle
 Packaging cost target = < $50
 Meet OOBE requirements
 Out-of-box experience (OOBE)
 Fast and easy setup; similar to inkjet printer
 All materials needed for first print shipped in single package
 User printing first model < 1 hour
6

7. A Closer Look at Mojo
7

8.  Why partner with Chainalytics?
 Stratasys does not have in-house packaging expertise
 Stratasys has previously partnered with Chainalytics on other
packaging optimization activities
 Previous work (Uprint, Tidalwave)
 Analytics and redesign solved previous issues
 Product design input and expertise
 Quick turn around on prototypes
Stratasys & Chainalytics Partnership
8
20122010
Concept
Development
System
Design
Final
Development
Production
Chainalytics’ initial look

9. Product Design
for Distribution
9

10. Product Design Input from Chainalytics
10
Fragile hood
Motor mounts
Y Bearings
3 Axes (lock down)
Head (lock down)
Material boxes
Purge buckets
Oven door
Fragile front bezel

11. Risk Matrix
11
Damage Risk Risk Design Option
Redesign
Cost
Packaging Option
Packaging
Cost
1
X-axis and Y-axis motion with no built in lock-down
mechanism. Restraint of x,y stages on top will be a
challenge because the drive belt is a single serpentine.
Also need clearance for head socket cables.
damage to x,y stages; out of
spec; damage to belt or belt out
of tension spec
High
*design home position with lockdown (i.e.
paper printer head)
*design ear on y-block casting to pin lock
thru top sheet metal/oven (restrain y)
*design hole thru head socket/shroud to pin
lock into top sheet metal (restrain x)
TBD
*dense foam or 'rigid' material to
fit around y-block carrier and
against front and back blocks to
restrain in y
*big block 'o foam over main
head socket to restrain in x
Med & High
2
Z-axis motion with no build in lock-down mechanism. Z-
stage is housed mainly in an insulated oven – the floor
is thin sheet metal and that floor is the only supporting
surface to use to isolate the stage. The oven is
suspended from the top.
damage to z stage/plate/arms;
out of spec; damage to oven;
damage to ball bearing/wave
spring.
High
*design home position with lockdown
*notch foam corners on bottom corners of
oven (foam tooling change)
*add 2 corner blocks or forms thru bottom
sheetmetal that oven can rest/attach onto.
TBD
*packaging underneath z arms
at back of oven to restrain in z
Med
3 XYZ motors may shift in transit
damage to belt; tension out of
spec
Med
* use star washers/loc-tite to secure
* change top sheet metal hole pattern in u
motor to eliminate slot adjustment & make
stationary; verify enough adjustment
remains in v motor slots; may need to
change motor bracket
TBD TBD TBD
4
Hood is fragile and cannot withstand transit
environment. The front of the hood is restrained from
x,y motion with some plastic standoffs mated on bezel
hood breaks/cracks; hinges
may be damaged
High
*radius sharp corners around hood
handle/bezel standoffs
*add more radius supports around inside
hood
TBD
* big block 'o foam to bridge
under hood and transfer load to
frame/sheet metal
High
5
Bezel is fragile and cannot withstand transit
environment.
bezel breaks/cracks High
*roll form front edge of sheet metal on
left/right skin sides to add rigidity; or
alternatively box form left/right skin sides
*add ribs on left/right insides of bezel
TBD
*corner foam to transition load
away from corners
High
6
Material boxes do not currently have a mechanical lock-
in retention feature
print head damage; box or tube
damage; spool cracks
Low *add lock down tabs over box TBD
*big block 'o foam with pocket to
retain boxes
High
7 Part/Support head sockets have no lock down feature
damage to head socket buckets
or leaf springs; alignment out of
spec
? *design lockdown feature or home position TBD
*tape foam down onto head
socket buckets to shroud
Low
8 Purge buckets are snap fit.
may come loose or shear off
pins thru bottom of oven
High *make pin stronger/bigger TBD
* tape down purge bucket lips
* do not snap purge bucket into
hole, ship 'loose' or in another
location
Low
9 Oven door has no transit lock feature
may come loose; damage to
hinge
Low *design lockdown feature TBD
*packaging option could be as
simple as a piece of tape
Low
Solo product design challenges:

12. Product + Package = Environment
Product Design
12
Optimal
Packaging
System
Measures taken to
reduce product
damage and improve
customer satisfaction
will invariably increase
package costs. The
optimal packaging
system balances
damage costs with the
cost of the package.

13. Final FormInitial Rendering
Non-Structural Hood
13

14. Closing the Gap
14
Initial hood design had
a “reveal” feature along
the sides
Need: Direct forces through
the chassis

15. Design Considerations for Shipping
15
X
Z
Restrain Y-axis on both sides.RECOMMENDATION

16. Design Considerations for Shipping
16
4 slots per motor head
Reduce adjustments for X and Y-axis belt tension.RECOMMENDATION

17. Product
Testing
17

18. Testing Criteria per Stratasys Protocol
 Product Fragility Testing
 Shock (all axes)
 Increasing shock levels to Δv ~ 50g
 Vibration
 Sine Sweep: 3-100Hz; Dwell 15 minutes @ 3 peaks
 Transit Testing
 Impact: 26 drops from 24”
 Vibration
 Sine Sweep: 3-100Hz
 Random (60 minutes all axes)
18

19. Resulting Product Changes
 New all plastic side skins: Not load bearing
 Hood hinge design change based on product testing
 Testing indicated hood may survive transit forces
 Material boxes (weights, packaging, and restraint)
 Need simplified, lower cost socket head restraint
19
 Reduced weight of material
boxes; easier to retain
 Box-in-Box concept appears to
be successful
 Hood may be okay to stay
attached
 Overall lighter weight may
require higher drop height
 Plastic skins more susceptible
to fractures
 May need 4” foam thickness
Risk Impacts

20. Distribution
Testing
20

21. Testing Protocol Overview
 Very complete legacy protocol
 No current Stratasys packaging engineers
 Stratasys needed a simplified interpretation
 Chainalytics created a custom software tool
 Inputs are simplified
 Output is a complete test plan
21

22. Stratasys Packaging Test Protocol Software
22

23. Stratasys Packaging Test Protocol Software
23

24. Stratasys Packaging Test Protocol Software
24

25. Packaging
Design
25

26. Review of Packaging Design Attributes
26
Packaging Design Attributes
Weighting
Factors:
(5 = most
important)
Order of
Importance
1
Product protection - shock and vibration (Must pass ASTM
D4169 standard to survive small parcel), moisture and
corrosion (VCI Bag or dessicant),
5 1
2
"Out of Box" package opening experience - per requirements -
30 minute to set up and assembly with 95% success rate on
first try w/ no assistance, no tools req'd (other than box cutter)
5 2
3 Environmental impact - sustainability and disposability 4 3
4
Cost of packaging (less than $45) per unit, as well as
availabilty and ability to source
4 4
5 Packaging size / shipping cost (sized to fit _____ pallet) 3 5
6
Sourcing - local availability and available in required
implementation timing
3 6
7 Labor required for packing 3 7
8 Handling - need hand holes for carrying 2 8
9
Return shipments - Packaging will need to be shipped to
customer for return shipments and product service
2 9
Weighting Factors:
1 = Lowest Importance
5 = Highest Importance

27. Preliminary Cushioning Concepts
27

28. Cushioning Layout & Specifications
28

29. New Options for Linear Bearing Restraint
29
X-axis corrugated Y-axis: Rigid plastic

30. Accessories Box
30

31. Final Internal Packaging
31

32. ExternalInternal
Final Pack-out Configuration
32
 Start-up Kit: Oven box
 X and Y-axis shipping stops
 Material bay strapping
 EPE endcaps and
strapping
 Poly bag and corrugated
box

33. The Best Laid Plans …
33
“We need
more foam!”
Information –
Pass it on!

34. Takeaways
 Packaging engineering input is needed early and often;
especially for new products and new technologies
 Testing and video can identify product design weakness
 Customer experience and expectations can drive design
 Test protocol and distribution environment drives
cushioning design and cost
 Outside resources may have needed expertise
34

35. Questions?
35

36. 36
Eric Carlson
eric.carlson@chainalytics.com
Rich Lindgren
rich.lindgren@chainalytics.com
Jeff Tronnes
www.packaging-matters.blogspot.com