Packaging Project
As this project is ongoing, only limited images of my work is available here.
I led a group of engineers through the design process to develop a range of concepts and prototypes to present to management. The selected design was a 100% Recycled PET packaging tray for a new product. This concept was developed further, creating prototype vacuum forming tools through to trial production tools.
I have continued to work alongside other engineers and with suppliers to ensure that the packaging meets the requirements for the project. This packaging will be tested to the ISTA 2A transport standard to confirm that product will be protected through transport and storage.
Left image: 3D Printed vacuum forming tool
Tooling
The design and mould tools were developed using Creo CAD software. I used Autodesk Powermill CAM software to create the tool paths to machine the mould seen on the left.
Two inserts were used in this tool to allow undercuts to be machined.
Rightmost picture shows the vacuum channels and holes to meet the 1mm holes that are drilled into the top side of the mould.
Vacuum Holes
I had to drill 64 1mm holes by hand which allow the vacuum to suck the plastic into the mould without any visual imperfections.
This was a difficult task, the right photo shows the drill bit graveyard after all the holes were complete.
Plug and Final Product
A negative mould or 'plug' was also machined to preform the plastic. This helps to reduce material thinning and webbing in sharp sections.