Custom Box-Shaper Tooling

This project involved the development and manufacture of custom tooling for a box-forming machine. The tool supports and guides a cardboard blank while pressure is applied, helping the machine form the required box shape consistently.

Project objective

The objective was to create a purpose-built tooling insert that matched the box geometry, fitted the existing machine and could withstand the forces applied during the forming process.

Development process

The geometry was refined through several printed test pieces before the full tooling body was produced. This iterative approach allowed mounting points, clearances and contact surfaces to be checked before final assembly.

Reinforced construction

The main structure was manufactured using FDM 3D printing, while steel plates were added at the contact areas to reinforce the assembly and provide more durable working surfaces.

Fit and application

The completed tooling was checked with the actual cardboard blank to verify its fit, alignment and contact geometry before installation on the box-forming machine.

Capabilities: custom tooling development, FDM prototyping, hybrid polymer-and-metal assemblies, fit testing and practical manufacturing support.