This document discusses how Unisource Engineered Solutions used 3D printing to create more realistic packaging prototypes. Specifically, it describes how UES used an Mcor Matrix 3D printer that prints with standard office paper to produce durable paper prototypes of their thin-walled, molded pulp packaging. These realistic prototypes enhanced customer understanding, satisfaction and increased sales by preventing confusion between prototypes and final products. The paper prototypes also provided benefits like shortened development time, reduced costs and an improved perception of UES.

1. Creating Realistic
Packaging Prototypes
with 3D Printing
Matthew Pray and Michael Storey
Managing Partners
Beckatt Solutions
November 5th, 2014

2. Overview of 3D Printing
• What is 3D printing?
• Materials
• Industry growth

3. Who is Using 3D Printing
• Industries
• Companies
• Consumers

4. Software
• CAD
• 3D Modeling
Software
• SolidWorks,
SpaceClaim,
Inventor, etc.

5. $64,000 Question
Why use 3D Printing for Packaging?

6. Packaging Applications

7. Prototyping/Concept Modeling
• Ease of concept change
• Tangible products to
present internally and
Externally
• Design understanding
• Time to market
• Exceed customer
Expectations
• Simulation of final
product
• Visual selling capabilities

8. Additional Uses
• Molds for thermoform
packaging
• Sleeve shrink
visualization

9. Smart to Market
• Concept to sample
• Consumer perception
• Speed up your engineering
productivity
• Cost savings (e.g., labor and
materials)
• Bring multiple options to
the table
• 3D is the wave of the future
• Win more sales!

10. Flexible Packaging
• Mcor Flex
• Living hinge capabilities

11. Paper-Based Printing
• Low cost of
consumables
• Full color capabilities
• Eco-friendly
• Final product
comparison
• Durability
• High resolution

12. Creating Realistic Packaging Prototypes
with 3D Printing Case Study
Unisource Engineered Solutions
We build on our in-depth materials knowledge,
practical experience and strategic
manufacturing relationships to create packaging
solutions that add value to your product,
help reduce total cost and strengthen your
competitive advantage.
(Source: www.unisourceengineeredsolutions.com)

13. Unisource Engineered Solutions (UES)
• One of the largest independent distributors and
marketers of 150,000+ national and private-label
products in North America
• Division of Unisource Worldwide
• Founded in 1968
• Headquarters: Norcross, Georgia (with offices
worldwide)
• Combine science and art to create high-impact
product packaging solutions
• Committed to innovation and sustainability

14. Challenges
• Thin-walled packaging from
bamboo pulp and sugar cane
residue (Bagasse)
• Hollow packaging for each
packaged part
• Plastic prototypes don’t
resemble final packaging
• Customers could be confused
when final product is not
similar to prototype
• Sales can be derailed

15. Objectives
• Create more realistic
prototypes
• Enhance customer
understanding and
satisfaction
• Increase sales

16. Strategy
• Design in SolidWorks
3D CAD and ArtiosCAD
software
• 3D print prototypes of
molded pulps with
paper in house

17. 3D Printer Selection Criteria
• Paper build material
• Durable
• High-resolution
• Folding materials
and boxes

18. Decision: Mcor Matrix 3D Printer
• Uses standard office paper
• Durable
• High-resolution
• Long-lasting living hinges
• Low material costs
• Fast, easy, safe, eco-friendly
• Proven success in another division

19. Results
“The
Matrix is
an
important
cog in
helping us
make the
sale and
delight the
customer.”
-UES

20. Results
“The Matrix is
an important
cog in
helping us
make the
sale and
delight the
customer.”
-UES

21. How It Works
Selective Deposition Lamination (SDL)
Mcor SliceIT digitally slices 3D design into layers matching thickness
of the paper.
Electronic slices sent to the printer one by one, similar to how a PC
sends pages of a standard document to a 2D printer.
Height-adjustable Tungsten
carbide tip cuts the shape of the
prototype.
Water-based adhesive deposited
in tiny dimples, by precision
delivery system.
Adhesive concentrated on the area inside
the model, while the unneeded material is
only very lightly held together, enabling fast
and easy prototype removal.

22. How It Works
Selective Deposition Lamination (SDL)
Cut Repeat
Press
Next Sheet
Adhesive
First Sheet

23. How It Works
Selective Deposition Lamination (SDL)
Load A4/letter
paper & adhesive
Setup build and remove part

24. Load Paper
Printer loads the next
sheet
3D printed object is
ready
Open 3D object in
SliceIT software
Click “Print Model”
First layer is cut Adhesive applied & sheets
squeezed together
Remove build plate Pull away
surrounding paper

26. Results
• Durable paper prototypes closely simulate final packaging
• Customers understand designs from the start
• Customer expectations exceeded
• Customer satisfaction increased
• Win more sales
• Prototype costs cut (5% of plastic)
• Shortened time to market (1 week vs. months)
• Additional uses: molds for thermoform packaging and prototypes of
products from which packaging is designed
• Green process and recyclable prototypes
• Innovative, world-class technology enhances perception of UES

27. Contact Beckatt Solutions
Matthew Pray
mpray@beckatt.com
630.206.3993 x 255
Michael Storey
mstorey@beckatt.com
630.206.3993 x 245
www.Beckatt.com
www.McorTechnologies.com