PACKAGING

THERMO-FORMED PACKAGING

PURPOSE OF THE PROJECT - To develop an adaptable & repeatable procedure with which to create tooling to produce vacuum-formed packaging faster and more cost efficiently than traditional methods.

The objective of this procedure is to create a digital 3D model of the packaging design for initial review. In following this procedure, digital models of the vacuum-form tools are concurrently generated and can be printed out with a Rapid Prototyping system. These tools (or patterns) can be used in conjunction with a vacuum-form machine to “prototype” the package design. The digital 3D models can also be used in the production of permanent vacuum-form tooling.

CLIENT - IMAGE ENGINE - demonstration project

PROJECT DATE - December, 2006

PROGRAMS USED - FREEFORM V-9


	The “Bump In The Night” TV series was based upon a small creature (Mr. Bumpy) who resides under the little boy’s bed. As the bed motif is used as the TV show logo, It was a good place to begin.

	A model of the bed was constructed using the Mr. Bumpy figure as a size reference.


	Additional shapes are added to the model in order to accommodate the figure and to ease the “draw” over the small details when the cover is vacuum-formed.




		The logo and the “sealing flange” are added to complete the tool.


		By employing one of Freefrom’s more unique tools, the model is extruded and trimmed to create the basic shape of the “outer blister”.


	A reasonably durable package is required, therefore an outward offset of .035” was generated from this solid shape. By engaging FREEFORM’s “shelling” & trimming tools, a model of the “blister” cover is produced.


	The next step is to produce a model of the “positioning tray” that will hold the figure in place within the package.



	In order to insure the fit of the “positioning tray”, data is extracted from the model of the outer cover in the form of a profile curve.





	This profile curve is then used to extrude a blank shape that will serve as the basis for the “positioning tray” model.


	FREEFORM’s unique extrusion tools and surface offset capabilities are used to generate a cutting tool that will cut the pocket in the surface of the “positioning tray” that is to accommodate the figure.



				FREEFORM’s surface offset capabilities permit accurate & consistent “fit tolerances” to be established & maintained between the product and the packaging.



		“Shelling” & trimming completes the model of the “positioning tray”.


		The last step is the creation of the cardboard backing & related graphics.