Unlock better ROI and Sustainability with FDM printing

FDM 3D Printing Service Online - JLC3DP is one of the most cost-effective and widely used 3D printing technologies in industrial manufacturing. Known for its accessibility and material versatility, FDM printing can significantly reduce the production time and expenses of applications, like jigs and fixtures, end-of-arm tools, and other assembly aids. For years, manufacturers have turned to additive manufacturing to accelerate tool-making and reduce costs compared to traditional fabrication methods

As materials evolve, high-performance FDM filaments include options that are electrostatically dissipative, chemically and heat resistant, or biocompatible, making them suitable for demanding industrial environments.

Challenges of traditional tooling

One of the industries that could benefit more from additive manufacturing is the packaging industry. While consumers often overlook the design and construction of packaging, it’s a field that involves significant planning, cost, and innovation.

Take the packaging of an electric razor, for instance - it often includes a protective paper element in the middle within a paper box, each product requiring custom tooling to produce. Through this example, we can break down the costs of manufacturing.

 source: iStock

In general, there are fewer paper elements compared to plastic ones, and the only obstacle to the wider spread of paper pulp packaging is the expensive and time-consuming metal tool machining.

The traditional method of creating these metal molds (typically aluminium or bronze) is a slow process that begins with the use of a milling machine. Then it is followed by a very labour-intensive step, which can even take up to a couple of weeks, assembling a handmade stainless-steel mesh to prevent clogging. Once this mold is done, it can be applied to the production line of the paper pulp elements, but it also has to withstand temperatures up to 170°C during the process.

FDM printing: a real game-changer in mold production

Thankfully, heat-resistant FDM filaments are available today, making it possible to replace expensive metal molds with a cost-effective 3D printed solution.

Fused Deposition Modelling has the potential not just to significantly reduce the cost of mold manufacturing, but to accelerate lead times from weeks to days. The results speak for themselves.

High tooling costs and long production times don’t allow many companies to present their prototypes economically in time to their clients. FDM printing can be a viable solution in order not to lose any clients. The case study also shows the cost comparison as the average cost of manufacturing tools, whether it was 3D printed or made by a CNC machine.

How to optimize FDM printing for paper pulp molds

To create breathable and completely permeable models required for paper pulp packaging, it’s essential to fine-tune the 3D printer settings. The key is to disable the automatic contour layers to maintain porosity, besides finding the right filament deposition for airflow. With traditional settings, the printer would finish up the model with an extra contour layer, blocking the important porous feature. This minor change helps to create perfect, production-ready parts.

Key Facts You Should Know About ABS Filament has great mechanical properties, such as good tensile impact and flexural strength, which is essential to use this material as a paper pulp mold. It’s a durable material with high temperature resistance.

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Prototyping flexibility and better ROI results

Even pilot tests have demonstrated the durability and precision of FDM printed molds during actual paper pulp production. The printed molds held up well, producing high-quality packaging parts with no visible degradation, suggesting strong potential for long-term use.

This technological change supports the current process of paper pulp molding, it aligns with the current production lines. With the help of 3D printed tools, small series productions of unique and complex geometrical packaging can become more practical and cost-effective.

Not so long ago, manufacturers couldn’t even imagine how they could save money on these molds, but now it’s worth reconsidering. It's only a matter of time before more packaging companies explore the full potential of 3D printed molds.