Case Study: Birdstone validates packaging design and accelerates product development with clear 3D‑printed prototypes from 3D Systems

Birdstone Proves Packaging Design with Clear 3D Printed Prototypes

Birdstone worked with Australian food brand Carman’s to design a tray insert for its new Super Seed & Grain Crackers that would protect fragile biscuits, present them attractively and meet production and retail constraints. The brief required easy filling on the production line, three-column stacking without crushing, reclosability for storage, vertical shelf display and on-shelf stability, so multiple accurate prototypes were needed quickly to validate form and function.

Birdstone partnered with 3D Systems to produce rapid, water-clear prototypes using SLA on a ProX® 800 in Accura® ClearVue™, finishing them to high optical quality in four days and then casting additional urethane copies for testing. The prototypes supported manufacturing and consumer testing and led to a one-piece clamshell design that is easy to fill, stylish to serve and securely reclosable—delivering supply‑chain efficiency, stronger brand experience and market recognition as a Packaging & Processing Innovation & Design Awards finalist.

Birdstone

Grant Davies

Director, Design & Strategy