BMT, a strategic technology partner for packaging, will present its Smart prototyping platform at Drinktec 2025, stand C6-531. The platform integrates virtual stretch blow moulding simulation, 3D-printed moulds and lab-scale testing to accelerate and de-risk bottle development. Following a measure, digitise, execute methodology, the approach prioritises data capture and engineering insight over trial and error. By recording real-time temperature, pressure and material behaviour, the system supports early optimisation of preform geometry, material selection and processing parameters before committing to production tooling. Core elements include BMT's Blowscan lab-scale SBM machine and Thermoscan thermal profiling, used together with techniques such as preferential heating and balayage to achieve controlled preform temperature and material distribution. According to the company, bottles blown with 3D-printed moulds on Blowscan can match production-grade quality while shortening the concept-to-prototype window from weeks to days.
"In today's fast-paced, fast-moving consumer goods market, brands face relentless pressure to bring new packaging to market quickly, making rapid prototyping a standard practice," said 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."
Methodology: measure, digitise, execute
Smart prototyping follows a structured methodology that emphasises insight generation over purely iterative testing. By capturing real-time data on temperature, pressure and material behaviour, BMT aims to enable optimisation of preform geometry, material selection and processing parameters long before mass production. Blowscan and Thermoscan operate in tandem and can be combined with preferential heating and balayage, providing granular control of preform temperature profiles and material distribution. The goal is to build a robust digital and experimental basis for decision-making early in development.
SBM simulation
BMT's signature stretch blow moulding 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 optimisation and verify performance virtually. By making informed decisions at this stage, costly modifications later in the process can be avoided.
Advanced testing
Small batches of bottles are produced under controlled conditions using 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. The resulting datasets support targeted design iterations and validation of processing windows.
3D-printed moulds
By using 3D-printed moulds, BMT reduces the time from concept to prototype from weeks to days. The tooling is designed to integrate with Blowscan, enabling fast turnaround, rapid testing and design iterations while generating performance data that can guide final production decisions. Comparative studies cited by the company confirm that 3D-printed moulds 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."
