This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

Integrating the physical and digital worlds is key to driving sustainable packaging solutions. Using a structured '˜Measure, Digitise, Execute'™ approach, BMT combines physical testing with digital prototyping to streamline the development of lightweight, high-performance packaging through stretch blow moulding (SBM), advancing sustainability while maintaining functionality and manufacturability. The process begins with Measure, where comprehensive data is acquired on the material, process, and product performance. Material data is collected using biaxial tensile testing and freeblow testing, enhanced by digital image correlation, to precisely capture the material'™s behaviour under SBM conditions. Process data is gathered via in-line and off-line temperature and pressure measurement systems, while product performance data is obtained using industry-standard tests such as top load and burst tests, facilitated by BMT'™s laboratory equipment. This multi-dimensional data forms the basis for model calibration and validation, ensuring high-fidelity simulations. In the Digitise phase, the collected data is used to calibrate representative material models for physics-based finite element simulations, integrating temperature and process data to ensure realistic performance predictions. Virtual prototyping is then carried out to explore opportunities for lightweighting, design innovation and sustainable material substitution. By combining simulation with design of experiments (DOE), data is generated across the design space, which is then used to train ML surrogate models. These models continuously learn and improve, enabling efficient exploration of the design space. Once well-trained, these surrogate models are employed to identify Pareto fronts, providing insights into trade-offs between key objectives such as lightweighting, structural integrity, and user experience. Finally, in the Execute phase, optimised designs are validated through physical prototyping and testing. BMT uses 3D-printed moulds to rapidly produce prototypes in-house, significantly reducing the time and cost associated with traditional mould production. This enables quick iteration and validation, with the entire process'”from design ideation to physical validation'”often completed within a week. This approach ensures that designs meet performance targets while minimising material usage and waste. BMT'™s Measure, Digitise, Execute methodology provides a robust framework for accelerating the development of sustainable packaging solutions. By bridging the gap between the digital and physical worlds, BMT effectively addresses complex design challenges in the packaging industry, advancing sustainability while ensuring product quality and functionality.