Work

Improving Geometric Formability in 3D Paper Forming Through Ultrasound-Assisted Moistening and Radiative Preheating for Sustainable Packaging

Year: 2025

Type: article

Abstract: In response to increasing sustainability demands, the packaging industry is shifting toward paper-based alternatives to replace polymer packaging. However, achieving complex, three-dimensional geometries comparable to plastics remains challenging due to the limited stretchability of paper. This study investigates advanced preconditioning techniques to enhance the formability of paper materials for deep-draw packaging applications. A custom-built test rig was developed at Syntegon Technology GmbH to systematically evaluate the effects of ultrasound-assisted moistening and segmented radiative heating. Under optimized conditions, 2.67 s moistening, 70.00 °C punch temperature, and 2999 W radiation power, maximum stretchability increased from 13.00% to 26.93%. The results confirm the effectiveness of ultrasound in accelerating moisture uptake and radiation heating in achieving uniform thermal distribution across the paper substrate. Although prototype constraints, such as the absence of inline conditioning and real-time measurement, limit process stability and scalability, the findings provide a strong foundation for developing industrial 3D paper forming processes that support sustainable packaging innovation.

Source: Journal of Manufacturing and Materials Processing

DOI: 10.3390/jmmp9080253

Authors: Heike Stotz, Matthias Klauser, Johannes Rauschnabel, Marek Hauptmann

Institution: Fraunhofer Institute for Process Engineering and Packaging Dresden

Language: English

Topic: Material Properties and Processing

Subfield: Mechanics of Materials

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $2,172