BMT, a strategic technology partner for packaging, will present its Smart prototyping platform at drinktec 2025, stand C6-531. The approach integrates virtual simulation, 3D-printed moulds and lab-scale testing to shorten development cycles for bottles while improving decision quality before industrialisation. The platform is positioned to help fast-moving consumer goods brands progress from concept to validated design within days, limiting late-stage changes and associated costs.
Smart prototyping follows a measure, digitise, execute methodology that prioritises actionable insight over iterative trial and error. By capturing real-time data on temperature, pressure and material behaviour, manufacturers can optimise preform geometry, material selection and processing parameters long before mass production. Two core technologies, Blowscan and Thermoscan, work with techniques including preferential heating and balayage to give granular control of preform temperature and material distribution.
“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 optimised to ensure top bottle performance and deliver an exceptional consumer experience. This is where innovations such as virtual simulation, 3D-printed moulds and lab-scale testing give FMCG manufacturers a decisive competitive edge.”
SBM simulation
BMT’s stretch blow moulding simulation applies advanced material models to evaluate designs from preform to final bottle before any physical prototype is made. Engineers can predict bottle formation, identify areas for optimisation and verify performance virtually. Making informed decisions at this stage reduces the need for costly modifications later in the process.
Advanced testing
Small batches of bottles are produced under controlled conditions using Blowscan, a lab-scale stretch blow moulding machine. With Thermoscan technology, the full temperature profile of the preform is captured. In parallel, pressure data and material distribution are tracked in real time, building a detailed picture of how the bottle forms and behaves during processing.
3D printed resin mould
3D-printed moulds
The use of 3D-printed moulds cuts time from concept to prototype from weeks to days. Tooling is designed to integrate with Blowscan, enabling fast turnaround, iterative testing and rapid design adjustments while generating performance data to guide final production decisions. Comparative studies cited by the company indicate that 3D-printed moulds used with Blowscan deliver bottles that match production-grade quality while significantly 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.”
