BMT (Blow Moulding Technologies), a strategic technology partner for packaging, will showcase at drinktec (C6-531) its SMART prototyping platform, which combines virtual simulation, 3D-printed molds, and lab-scale testing to accelerate and de-risk bottle development.

“In today’s fast-paced, fast-moving consumer goods (FMCG) market, brands face relentless pressure to bring new packaging to market quickly, making rapid prototyping a standard practice,” says Yannis Salomeia, BMT CEO and Co-Founder.

“However, speed alone isn’t enough—designs must be optimized to ensure top bottle performance and deliver an exceptional consumer experience. This is where innovations such as virtual simulation, 3D-printed molds, and lab-scale testing give FMCG manufacturers a decisive competitive edge.”

Measure, Digitize, Execute

SMART prototyping follows BMT’s “measure, digitize, execute” methodology, focusing on gathering insight rather than relying solely on iterative testing. 

By capturing real-time data on temperature, pressure, and material behavior, BMT enables manufacturers to optimize preform geometry, material selection, and processing parameters long before mass production.

BMT’s SMART prototyping utilizes two core technologies, BLOWSCAN and THERMOSCAN, which work in tandem with new techniques—including preferential heating and balayage—to deliver unparalleled insights that allow for control over preform temperature and material distribution.

SBM simulation

BMT’s signature Stretch Blow Moulding (SBM) simulation uses advanced material models to assess new designs from preform to final bottle before any physical prototype is made. Engineers can predict bottle formation, identify areas for optimization, and verify performance virtually. By making smart decisions at this stage, costly modifications later in the process are avoided.

Advanced testing

Small batches of bottles are produced under controlled conditions using BMT’s BLOWSCAN, a lab-scale SBM machine. With THERMOSCAN technology, the full temperature profile of the preform is captured. At the same time, pressure data and material distribution are tracked in real time, providing a detailed picture of how the bottle is formed. 

3D-printed molds

By using 3D-printed molds, BMT cuts the time from concept to prototype from weeks to just days. The tooling is designed to integrate seamlessly with BLOWSCAN, enabling fast turnaround, rapid testing, and design iterations while generating valuable performance data to guide final production decisions.

Comparative studies confirm that 3D-printed molds used with BLOWSCAN deliver bottles that match production-grade quality while dramatically reducing prototyping time.

“These enhancements reinforce our mission to deliver actionable insights, not just speed,” said Jude Cameron, Project Lead at BMT. “With SMART prototyping, manufacturers can progress from concept to validated design in a matter of days—reducing costs, mitigating risks and accelerating time to market with greater confidence.”