Case Study: PepsiCo achieves 10M+ social media impressions with Protolabs' Multi Jet Fusion 3D‑printed Black Panther mask

PepsiCo R&D Team Elevates Packaging Design with 3D Printing

PepsiCo’s R&D packaging team needed a manufacturing solution for low volumes of highly complex parts to support a limited-edition promotional kit tied to the Black Panther movie premiere. They required detailed, durable components (only 250 masks) that could be produced economically and shipped reliably—so PepsiCo turned to Protolabs for 3D printing services, selecting Multi Jet Fusion (MJF) for its precision and finish.

Protolabs delivered MJF-produced replica Black Panther masks and provided rapid turnaround and DFM support to meet a tight sub-six-month schedule; the parts passed distribution vibration, compression, and drop tests and were specified to retain deep black color and durability for years. The assembled kits, which included the 3D-printed mask, were distributed to influencers and helped the campaign achieve more than 10 million social media impressions, demonstrating Protolabs’ impact on accelerated packaging design.

PepsiCo

Andrew Phinney

R&D Packaging Engineer