3D-Printed Packaging Line Change Parts: When MJF or FFF Makes Sense

How packaging equipment manufacturers can use additive manufacturing to develop custom guides, fixtures, and change parts while improving flexibility and reducing production delays.

Packaging equipment is designed for speed, precision, and repeatability. But when a production line needs to accommodate a new container, updated product design, or equipment modification, even a small plastic component can become a significant challenge.

Custom guides, brackets, change parts, and fixtures are essential to keeping automated packaging systems running efficiently.

Traditionally, these components have been machined or molded, often requiring additional lead time and tooling expense.

Additive manufacturing offers another option.

With technologies such as Multi Jet Fusion (MJF) and industrial Fused Filament Fabrication (FFF), packaging equipment manufacturers can develop and produce custom plastic components without traditional tooling.

The key is knowing which parts are good candidates, which manufacturing process makes sense, and how to ensure the finished parts meet the application's performance requirements.

Where 3D Printing Fits in Packaging Equipment

Modern packaging lines frequently handle multiple container sizes, product configurations, and production formats.

Each change can require adjustments to the components that guide, position, support, or transfer products through the system.

Many of these components are produced in relatively small quantities, making them attractive candidates for additive manufacturing.

Common applications include:

• Conveyor guides and transfer components: Custom-shaped guides that help direct bottles, cartons, and other products through automated equipment.

• Changeover parts: Format-specific components that accommodate different container sizes or product configurations.

• Star-wheel prototypes and positioning nests: Custom geometries used to evaluate product handling and positioning before committing to production tooling.

• Sensor and camera brackets: Custom mounting components for inspection and automation systems.

• Jigs and alignment fixtures: Tools that help operators position equipment components accurately during setup and maintenance.

• Guards, covers, and supports: Lightweight, application-specific components that protect equipment or support related assemblies.

For mechanical design engineers, the advantage is the ability to develop functional components, test them in the intended assembly, and refine the design without committing to expensive tooling.

MJF vs. FFF: Which Technology Makes Sense?

Both MJF and industrial FFF can produce functional thermoplastic components, but each technology offers different advantages.

The best choice depends on the component's geometry, mechanical loads, material requirements, production quantity, and operating environment.

Multi Jet Fusion (MJF): For Complex, Repeatable Production Parts

MJF uses a powder-based manufacturing process to produce functional thermoplastic components with detailed geometries and relatively consistent mechanical properties.

For packaging equipment applications, MJF is particularly attractive when parts require:

• Complex shapes, including curved guides and positioning features.

• Dimensional consistency across multiple components.

• Functional strength and durability.

• Production quantities that benefit from batch manufacturing.

• Freedom to integrate multiple features into a single component.

For example, a packaging equipment manufacturer developing a new container-handling system may need multiple custom positioning guides.

Rather than machining each component individually, MJF may provide a practical method for producing and evaluating the parts before moving into repeat production.

Where MJF adds value: Applications in which geometric complexity, repeatability, and reliable part performance are more important than simply achieving the lowest initial unit price.

Fused Filament Fabrication (FFF): For Plastic Components and Material Flexibility

FFF builds components by depositing thermoplastic material layer by layer.

Industrial FFF systems offer access to a range of engineering thermoplastics, making the process useful for larger parts, customized fixtures, and applications requiring specific material properties.

FFF may be a good choice for:

• Machine guards and covers.

• Custom mounting brackets.

• Changeover fixtures and setup tools.

• Low-volume components with relatively simple geometries.

• Applications requiring a particular thermoplastic material.

For example, an OEM may need a custom fixture to position a packaging component during assembly or maintenance. Industrial FFF could provide an economical solution, particularly when the design is too large or material-specific for a preferred MJF process.

However, because FFF parts have layer-dependent mechanical properties, build orientation and loading conditions must be evaluated carefully.

Where FFF adds value: Larger parts, material-specific applications, and low-volume components where industrial-grade process control provides the required performance.

Engineering Considerations Before Selecting 3D Printing

Not every packaging component should be 3D printed.

Before selecting a manufacturing process, engineers should consider several factors that directly affect reliability and long-term performance.

1. Dimensional Accuracy and Repeatability

Packaging equipment relies on precise positioning and consistent movement. Even relatively small dimensional variations can create alignment problems, unnecessary friction, or interruptions to product handling.

Critical mating surfaces, mounting locations, and part tolerances should be reviewed before manufacturing.

At SICAM, we emphasize controlled manufacturing processes to help customers achieve consistent, repeatable part performance.

2. Wear and Mechanical Loading

Parts that repeatedly contact moving products or equipment may experience abrasion, impact, or sustained loading.

The selected material must be appropriate for the component's operating conditions.

MJF nylon components can be suitable for many functional applications, while industrial FFF provides additional thermoplastic options for specific performance requirements.

In high-wear applications, conventional machined materials may still be preferable.

3. Temperature, Chemicals, and Cleaning Requirements

Packaging equipment may operate in environments exposed to elevated temperatures, cleaning agents, lubricants, or moisture.

Material selection should account for these conditions rather than focusing exclusively on strength or initial manufacturing cost.

For food, beverage, pharmaceutical, or other regulated packaging applications, direct product contact and sanitation requirements must also be evaluated.

A material's general suitability does not automatically establish that a finished 3D-printed component is approved for food contact or hygienic service.

4. Surface Finish and Product Handling

The surface condition of a guide or transfer component may influence friction, wear, and how smoothly products move through the equipment.

Depending on the application, surface finishing or additional post-processing may improve functional performance.

Engineers should evaluate the finished component under actual operating conditions rather than assuming that its as-printed surface will meet every requirement.

From Prototype to Production: Reducing Risk Before Scaling

One of the most valuable advantages of additive manufacturing is the ability to validate a component before committing to higher-volume manufacturing.

Consider a packaging equipment OEM developing a machine to handle a redesigned consumer product container.

The project might follow this process:

Step 1: Develop the CAD design

The engineer creates a custom guide or positioning component based on the new container geometry and machine requirements.

Step 2: Manufacture a functional prototype

MJF or FFF is selected based on the design, material, and testing requirements.

Step 3: Evaluate fit and performance

The component is tested in the intended equipment to verify alignment, clearance, product handling, and functionality.

Step 4: Refine the design

If testing identifies interference, excessive friction, or other performance concerns, the CAD model can be modified without changing production tooling.

Step 5: Transition to production

Once the design is validated, the manufacturer can select the most appropriate production method based on expected volume, performance requirements, and cost.

For some components, additive manufacturing remains the best long-term production solution.

For higher-volume applications, injection molding or another conventional process may become more economical.

The advantage is having the flexibility to make that decision after verifying the design.

Why Consistent Quality Matters More Than the Lowest Part Price

In a high-speed packaging environment, the purchase price of a component is only one part of its overall cost...

A poorly fitting guide or inconsistent replacement component can contribute to:

• Unplanned production interruptions.

• Increased equipment adjustments.

• Premature wear or component replacement.

• Additional maintenance and engineering time.

• Product handling or quality issues.

For critical applications, these potential costs can outweigh a modest difference in part price.

Your part's performance is the real outcome.

At SICAM, our focus is on helping engineers reduce manufacturing risk through appropriate technology selection, controlled production processes, and consistent quality.

Our ISO-certified quality management systems support a disciplined approach to manufacturing, helping customers make informed decisions about part performance and repeatability.

Partnering With SICAM for Packaging Equipment Components

Whether you're developing a new packaging machine, introducing another product format, or improving an existing automated system, selecting the right manufacturing method can make a meaningful difference.

SICAM works directly with mechanical design engineers to support projects from initial concept through production.

Our capabilities include:

• MJF 3D Printing: Functional prototypes and repeat-production components with complex geometries.

• Industrial FFF 3D Printing: Larger parts, custom fixtures, and applications requiring specific engineering thermoplastics.

• Engineering and Manufacturing Support: Assistance with process selection, manufacturability, and material considerations.

• Injection Molding: Scalable production solutions when application requirements and volume justify tooling.

Rather than treating every project as a one-time prototype, we help customers evaluate how their parts will perform and how they can be manufactured consistently as requirements evolve.

Ready to Improve Your Packaging Equipment Design?

Have a custom guide, changeover component, bracket, or fixture that needs to be manufactured?

Send SICAM your CAD file, expected quantity, and application requirements. Our team can help you evaluate whether MJF, FFF, or another manufacturing approach is the best fit.

Request a Quote from SICAM