Iconic PepsiCo Brand Finds Best Alternative to Expensive, Time-Consuming Conventional Metal Tooling

PepsiCo products are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo generated more than $79 billion in net revenue in 2021, driven by a complementary beverage and convenient foods portfolio that includes Lay’s, Doritos, Cheetos, Gatorade, Pepsi-Cola, Mountain Dew, Quaker, and SodaStream. PepsiCo’s product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.

Company

PepsiCo Inc.

Industry

Consumer goods packaging, food & beverage

Printer

Nexa3D NXE 400 Printer

Material

xPEEK147 by Henkel Loctite

Application

Applying its patented technology and a hybrid approach, PepsiCo is using additive manufacturing as an enabler in various aspects of bottle development – accelerating and enhancing performance simulation, advanced system analysis and the production of high-quality, functional prototypes.

Advantages

• Compress prototype tooling development time from 4 weeks to 48 hours
• Slash prototype tooling costs from $10,000 to $350 per mold set
• Create durable tooling that can produce more than 10,000 bottles per mold
• Enable multiple design iterations to allow for timely verification of downstream activities

More Than 10,000 Bottles at 96% Reduction in Cost

PepsiCo went with Nexa3D’s xPEEK147 from Henkel Loctite for the 3D printed tool inserts because of its strength and impressive performance features, like its high heat-deflection temperature. This hybrid approach can work with different types of 3D printers, but PepsiCo has found that the super-fast, high-capacity Nexa3D NXE 400 3D printer and its materials are perfect for making the mold parts they need.

A full set of molds can be produced in just 12 hours, with 8 hours of printing and 4 hours of curing. These hybrid molds can then be used for over 10,000 bottles before needing replacement – all at a cost reduction of up to 96% compared to traditional metal tooling.

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Ceramic 3D solutions for jewelry

Additive manufacturing enables the production of functional prototypes or the production of single or small series of parts. This service gives huge advantages in terms of responsiveness to the design department of the high end jewelry industry.

Ceramic is unalterable, hypoallergenic and provides a silk touch aspect. Ceramic material with the touch and feel of materials such as onyx or mother of pearl or with a polished / mirror finish, quickly attracted interest from renowned jewelers and watchmakers. 3DCeram helps you to choose the right type of ceramic for your project, according to its technical properties and luxury feel.

Advantage of technology

Thanks to 3DCeram expertise you could combine the advantages of ceramics and the benefits of 3D printing.

By doing away with the need to create a mold, the process can be used to produce just about any shape with extreme degree of complexity. A designer can free his creativity. He can imagine, create and see the fruit of his imagination laid before him in a very short time thanks to on demand manufacturing service offered by 3DCeram.

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The aim

Production of car parts, the fastest replacement of worn-out accessories, tuning the body and interior.

The solution

Printing of components with high-strength photopolymers, polyamides that can withstand even high temperature loads.

Some examples of additive manufacturing solutions for the automotive industry are:

• printing of wheel rims and unique emblems
• replacing wipers, lost or worn plugs
  printing of functional interior elements: handles, buttons, parts of the dashboard, printing of bushings, printing of individual body design elements – arch linings, sills
  printing of protective plastic elements for motorcycles
  printing of forms for subsequent casting of bumpers

Advantages and results

3D printing allows you to quickly produce functional parts in the automotive industry, as well as provide quick replacement of worn parts. 3D printing is highly efficient, in some cases the production time is reduced by 80% compared to traditional manufacturing methods, as well as the cost price can be significantly reduced. Additive manufacturing provides truly limitless opportunities for prototyping, maintenance, and tuning of cars and motorcycles.

Please note that the world’s fastest Nexa3D printer solves the challenges of the automotive industry on a turnkey basis.

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The aim

The opportunity to develop students’ spatial thinking and creative skills, as well as to quickly reproduce models, created by the students themselves.

3D printing is a powerful educational tool. Some examples of the educational use of 3D printing are:

• creation and visualization of complex objects
• mockups of process equipment
• imitation of a human body fragment or an organ
• complete reconstruction of historical, archaeological, or art related objects

Advantages

In addition to creative development and developing spatial thinking, students gain practical experience in prototyping, which later serves as an excellent incentive for choosing engineering professions. 3D technologies have a positive impact on the quality of education and on the program as a whole, because thanks to additive technologies, the training plan is supplemented with the basics of design, engineering, construction and modeling.

In addition, creating something with your own hands in real time helps to change the child’s thinking from consumption to generating ideas and creating. For the educational process, the Nexa3D printer is perfect, it can print a 3D model in a few minutes in a safe, secure and cost effective manner.

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The aim

High-precision printing of 300 molds of patient’s jaw models per day.

The solution

3D SLA printing on 3D Systems ProX 800 printer provides daily production of jaw models molds for hundreds of patients. It is possible to print about 300 items at the same time in 24 hours.

Advantages

• High print accuracy of 150 microns.
• High production speed.
• The model can be held by itself due to special software processing.
• Minimum support materials.
• Fast post-processing.

The result

Saving materials, production volume up to 16,000 items per month, and 40% manufacturing costs redaction of press-molds. Also, 3D printing successfully covers the needs of dental clinics in the production of individual materials for operations and other treatments, composite material crowns , ceramic and metal implants, bridges.
The world’s fastest 3D printer Nexa3D and ceramic printers 3DCeram solve any problems of dental clinics.

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The aim

To speed up the production of fasteners, speed up the assembly process, and reduce costs.

The solution

Using 3D printing allows you to produce fasteners for spacecraft and civil and military aircraft, while reducing production costs and time, and improving the productivity of the entire production.

Advantages and results

• Print one-piece part with an already established and collected items.
• Production of parts of complex shapes and geometries with minimal costs and in the shortest possible time.
• Reducing the weight of parts.
• Exception of errors during Assembly.
• Huge time savings on foundry processes and faster design iterations by eliminating time-consuming tooling.

High-quality solutions for the aerospace industry are provided using our own additive manufacturing equipment equipped with Nexa3D printers.

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The aim

To reduce the production time for a passenger aircraft part.

The solution

SLA printing with QuickCast technology has reduced the production time for bushing used in aircraft engines. The technology creates a solid shell of the model and is filled with a cellular structure, which increases the burnout process several times. It leaves no ashes, and the final part shape remains the same as the original 3D model.

The use of QuickCast 3D printing technology enables saving materials while producing the most detailed part with a high resolution. After assembling all parts, it was covered with a special ceramic composition, and the metal was poured into the mold. After solidification and removal of the form, the final part was taken out.

Conclusion

• The Quick Cast model replaces traditional casting models and does not require expensive tooling. Thus, the company reduced the cost of casting models by 95%.
• SLA printing reduced the production cycle by 3 months. Nexa3D printer solves a number of aerospace production tasks, as well as 3DCeram equipment, which produces ceramic parts for complex circuits.

The post SLA printing reduced the production cycle of an aircraft engine sleeve by 3 months appeared first on Dev.

The aim

The aerospace industry is constantly seeking to optimize the performance of its equipment (satellites, measurement tools, optical instrumentation, etc.) by exploiting the properties of ceramic materials. Of importance is the quick turnaround between design of components and delivery of these components. Ceramic 3D manufacturing offers an unique solution to the aerospace industry. You will be able to quickly design and manufacture complex and unique parts without large scale investments.

Advantage of technology

The ceramic materials used in 3D printing are very resistant and have exceptional physicochemical properties (eg. corrosion resistance, electrical insulation).
Ceramic products suffer too often from the limit of traditional means of manufacture, limiting their uses to massive parts and little stress. However, with 3DCeram printers, you have all the freedom degrees for the production of complex ceramic materials for the aerospace industry.

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One example is Nexa3D’s recent announcement regarding their plans to produce protective gear for healthcare and other essential workers. Established as a direct response to the urgent requests for PPE pouring in from healthcare facilities as well as other essential front line workers, Nexa3D partnered with key players in the medical industry to develop a face shield that is lightweight and designed to be worn for long periods of time while limiting facial exposure to aerosol and splatter. Recently, Nexa3D joined Henkel’s Open Materials Platform. Soon after, the two companies Announced their initial collaboration with the availability of Nexa3D 3843 xABS Black, which is based on LOCTITE 3D 3843 and optimized to run smoothly on Nexa3D’s machines. The company’s NXE400 printers are powered by it’s proprietary Lubricant Sublayer Photo curing ( LSPc ) technology and patented structured light matrix, allowing them to produce up to 19 liters of part volume at high speed, thereby reducing the time it takes to produce functional prototypes and production parts, often from hours to just minutes.

As new challenges arise, industry collaborations like those offered by Henkel’s Open Materials Platform will be available to help companies quickly react and meet the need. And when a new situation does arise, the experience gleaned from this emergency will prove beneficial in helping others better leverage the benefits of additive manufacturing in the future.

Explore What’s New in 3D Printing

• Nexa3D utilizes Loctite 3D printing material to produce face shields for thousands of front line workers

• Reconstructive surgery: the surgeon adjusts the medical device to the patient

• High-quality metal powder use to produce high-strength parts for various industries

• Aerospace optimization and manufacturing process improvement using ceramic 3D printing

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