How PakTech Improved Quality Testing with a Lightweight Carbon Fiber Tool
A Better Approach to Pull Force Testing
For PakTech, maintaining consistent product quality is a key part of its manufacturing process. The company develops plastic carrier handles and packaging systems for a wide range of consumer products, making reliable testing an essential part of production.
One important quality check involves determining the amount of force required to remove an anvil from a sealed container. This test was traditionally performed using custom-machined aluminum plates.
While the aluminum tooling delivered the required performance, it came with several practical drawbacks. The plates were heavy, expensive to manufacture, and required the company's tool room to spend valuable time machining replacements. This meant skilled machinists were often occupied with relatively simple testing equipment instead of more critical mold-making projects.
PakTech also needed to manage different container sizes and testing requirements. With several tools being used across the production floor, identifying the correct plate for each test wasn't always straightforward.
Moving from Machined Aluminum to 3D Printed Carbon Fiber
To address these challenges, PakTech redesigned its Pull Force Applicator for additive manufacturing.
The new plates were produced using Onyx GF, with carbon fiber reinforcement providing the stiffness and durability needed for regular factory-floor use. The components were printed in green, creating a clear visual identifier for tools designated specifically for Quality Department testing.
This seemingly simple change delivered multiple benefits.
The printed plates offered comparable rigidity to their aluminum predecessors while being significantly lighter and more economical to produce. At the same time, the team could manufacture the tooling directly from the printer without depending on the tool room.
Instead of machining a new plate whenever a change was required, engineers could modify the digital design, print an updated version, and put it into use much faster.
Why the Green Color Made a Difference
The use of color became an important part of PakTech's quality-control system.
By assigning green to Quality Department testing tools, operators could quickly recognize whether they were holding the correct applicator for a particular test. This provided a simple visual reference and reduced the possibility of using the wrong tooling during anvil force measurements.
The approach also created a more organized system for managing the different tools used across production.
Built for Everyday Industrial Use
Before adopting Onyx GF, PakTech had experimented with standard PLA prototypes. Although suitable for early-stage testing, the PLA components were not durable enough for continuous use in the manufacturing environment.
The combination of Onyx GF and carbon fiber reinforcement provided the strength and rigidity necessary for repeated daily operation.
The result was a tool that could withstand regular use while remaining considerably lighter than a machined aluminum alternative.
More Freedom in Tool Design
3D printing also gave PakTech greater flexibility when developing the applicator.
Rather than designing around the limitations of conventional machining, engineers could incorporate specific geometries and functional features directly into the printed component. This made it easier to optimize the applicator for different container and anvil configurations.
The team could also make design changes without restarting the entire machining process, making experimentation and iteration considerably more efficient.
The Impact on PakTech's Manufacturing Process
The redesigned Pull Force Applicator delivered improvements beyond the tool itself:
Less Dependence on the Tool Room
Quality testing tools could be produced independently, allowing machinists to dedicate more time to high-priority mold-making work.
Faster Tool Development
Engineers could move from a digital design to a functional tool without waiting for machining resources.
Clearer Tool Identification
The green finish provided an immediate visual cue for Quality Department equipment, helping operators select the appropriate tool.
Improved Durability
Onyx GF reinforced with carbon fiber provided the strength needed for repeated factory-floor use, overcoming the limitations experienced with PLA prototypes.
Greater Design Flexibility
Complex or customized features could be incorporated directly into the printed design, allowing the applicator to be optimized for different testing requirements.
A More Efficient Way to Build Production Tools
PakTech's Pull Force Applicator demonstrates how additive manufacturing can replace conventional metal tooling when the application calls for a lighter, faster, and more adaptable solution.
By combining Onyx GF, carbon fiber reinforcement, and color-coded tooling, PakTech created a durable quality-control component while reducing its reliance on traditional machining.
As Ronnie Mellor, Manager of Industrial Design Engineering at PakTech, explains:
“Printing allows us to do things we usually couldn’t with machined aluminum.”
For PakTech, the value goes beyond replacing one aluminum component. The ability to design and manufacture tools internally gives the engineering team more freedom, reduces pressure on the tool room, and helps turn new ideas into working solutions faster.