Birdstone Proves Packaging Design
with Clear 3D Printed Prototypes
3D Systems On Demand Manufacturing helps packaging design firm achieve
aesthetic and functional prototypes with clear SLA 3D printing
Anyone who has opened a box of
crackers to find the contents reduced to
broken bits and pieces knows firsthand
the consequences of poor packaging.
Carman’s, an Australian food company
passionate about only using the best
ingredients, is mindful of how it delivers
its products to consumers to ensure
a high quality experience before the
first bite is ever taken. Therefore, when
Carman’s launched its new Super Seed
& Grain Crackers, the food company
kept presentation and preservation
top of mind, and enlisted Birdstone, an
Australian packaging design agency,
to design an engaging tray insert.
Due to the various requirements they
needed to balance, multiple prototypes
previous successful collaborations.
(SLA) 3D printing on 3D Systems
ProX® 800 machine, 3D Systems built
were required to demonstrate the
proposed designs both aesthetically and COLLABORATING TO DELIVER both a one- and two-piece prototype
functionally. FUNCTIONALITY AND BUILD BRAND in Accura®ClearVue™, a rigid and tough
EQUITY clear 3D plastic material offering the
BALANCING CLIENT REQUIREMENTS IN Birdstone worked closely with Carman’s highest clarity and transparency on the
PACKAGING DESIGN marketing and product development market.
The packaging considerations in play for teams as well as its packaging supplier Carman’s were multifaceted: it needed to to review and narrow the packaging be easy to open, functional as a serving design concepts to two. From the outset, AESTHETIC PACKAGING
vessel, and enable Carman’s customers the top priority was to maintain supply In just four days, the SLA prototypes were
to reclose the container for storage. For chain efficiency throughout packaging printed and finished to meet Birdstone’s
ease of access, it was determined that manufacturing and product filling, quality and realism requirements. 3D
the crackers should be stacked in three followed closely by building brand equity Systems’ On Demand Manufacturing
columns with room to encase the top into the tray with an effective and hassle- experts followed the premium finishing
crackers without crushing them, but also free customer experience. Relaying this protocol for Accura ClearVue to deliver
be easy to fill to not disrupt the production information to 3D Systems On Demand water-clear prototypes through a process
line. Lastly, the packaging needed to Manufacturing, Birdstone and the 3D of wet and dry sanding followed by clear
meet the retailer requirement for vertical printing service bureau talked about the coating. These prototypes were then
packaging to maximize differentiation on requirements for the prototypes. submitted for manufacturing tests and
PROTOTYPING FUNCTIONAL AND
consumer research to validate and rate
the shelves. There was also a question of
on-shelf instability due to the light weight Due to the complexity of the casing the success of each concept, and to
of the product and the properties of the designs and unique functional assess the performance and limitations of
tray material. requirements involved, 3D Systems’ On each packaging option at all critical touch
Demand Manufacturing experts helped points.
Birdstone knew that arriving at the correct Birdstone select the most suitable design would require accurate prototypes, prototyping process, materials, and At this stage, Birdstone ordered
and therefore reached out to 3D Systems finishing process to meet its outlined four copies of the leading packaging
On Demand Manufacturing due to requirements. Using Stereolithography design from 3D Systems On Demand
52 FDPP - www.fdpp.co.uk