BMT (Blow Moulding Technologies) will present its Smart prototyping platform at Drinktec 2025, hall C6, stand 531. The approach combines virtual simulation, 3D-printed moulds and lab-scale testing to shorten development cycles and reduce risk in stretch blow moulded bottle programs. The methodology is based on the principle of measure, digitise, execute, with an emphasis on gathering actionable insight rather than relying solely on iterative physical trials. By capturing real-time data on temperature, pressure and material behaviour, Smart prototyping aims to optimise preform geometry, material selection and processing parameters long before scale-up. The platform integrates two core technologies, Blowscan and Thermoscan, applied alongside techniques such as preferential heating and balayage to achieve greater control over preform temperature and material distribution. According to the company, this integrated workflow is designed to move projects from concept to validated design in days, supporting faster time to market for beverage and other FMCG packaging while maintaining bottle performance targets.
Process and methodology
Smart prototyping follows BMT’s measure, digitise, execute framework. Measurement starts with instrumented trials that record temperature and pressure profiles and monitor material distribution during forming. Digitalisation uses these datasets to inform models and process settings, guiding decisions on preform design, polymer grade and stretch ratio before committing to tooling. Execution combines targeted lab runs with rapid mould iterations to validate findings. As BMT’s CEO and co-founder Yannis Salomeia notes: "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." He adds: "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 (SBM) simulation applies advanced material models to evaluate new 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. By making informed choices at this stage, projects can avoid costly modifications later in the development process.
Advanced testing
Lab-scale production of small bottle batches is carried out on Blowscan, BMT’s SBM machine configured for controlled trials. With Thermoscan, the full temperature profile of the preform is captured. In parallel, pressure data and material distribution are tracked in real time, providing a detailed view of how the bottle is formed under specific conditions. These datasets feed back into the simulation and help refine settings prior to industrialisation.
3D-printed moulds
Using 3D-printed moulds, BMT shortens the path from concept to prototype from weeks to days. Tooling is designed to integrate with Blowscan, enabling rapid turnarounds, iterative testing and the generation of performance data to support 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. Jude Cameron, project lead at BMT, said: "These enhancements reinforce our mission to deliver actionable insights, not just speed. 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."
