Design concept development for a flexible polymeric packaging

Abstract

Within the economic growth of Bosch Car Multimedia S.A., which is related to the increasing market demands for new and innovative multimedia products, the packaging solution employed for the internal transport and storage of electrostatic sensitive electronic systems generated an issue related to the company area employed for storage sections. It became necessary to introduce a new approach that is suitable for the safe transportation of such a diversity of electronic systems, while saving company space and improving the logistics associated. The development and optimization of a new concept design for a flexible polymeric packaging, based on structural simulation analysis, is presented in this paper. Preliminary concept designs were developed and refined by performing structural simulations to validate the structural strength when subjected to specific mechanical efforts. Two types of simulations were performed, maximum filling weight and free fall drop impact for the baseline (actual packaging) and the developed concept design for evaluation and comparison. The simulations output made necessary to further reinforce the initial concept by a combination of structural ribs and thicker features. The optimization of the initial design concept showed improved performance and structural suitability for the replacement of the actual packaging. Other design features that improve the handling and maintenance of the packaging were also considered. Functional prototypes were fabricated in additive manufacturing by means of FDM (Fused Deposition Modelling) process with the refined design concept.