Case-Study “Samplistick”

When developing new products, the choice of material, its suitability for the intended application and subsequent manufacturability play a key role. This was also the case for the development of the ‘Samplistick’ by the start-up of the same name. In this case study, we demonstrate how BARLOG Plastics helped bring the product to market quickly, reliably and cost-effectively by selecting a suitable material and providing comprehensive development services.

Project description

The ‘Samplistick’ project is an example of the successful collaboration between BARLOG Plastics and a start-up company. Through a combination of consultancy, simulation, laboratory testing and prototype production, the product was developed to market-ready status within a short space of time.

The “Samplistick” is already being used in various perfumeries across Germany for dispensing samples of perfume, make-up and skincare products. This gives customers the opportunity to test products in the comfort of their own homes before making a purchase decision.

Material selection

KEBALLOY® ECO E302 natural was used for this project. This is a material based on processed PET recyclate from used PET bottles.

The material meets the application’s requirements and offers the necessary properties for the manufacture of the Samplistick. Furthermore, the material used can be collected and recycled within existing recycling systems, provided that appropriate collection infrastructure is in place.

Development services

BARLOG Plastics developed a moulding concept for the Samplistick tailored to the product’s requirements.

The complex double-start thread was realised in the mould via the nozzle side, the ejector side and two additional sliders. This design enabled the requirements for functionality, precision and process reliability to be met.

In addition, an injection moulding simulation was carried out for the 16-cavity cold runner manifold system of the production mould. This enabled potential filling and warpage issues to be identified and addressed even before tooling production began.

In addition, BARLOG Plastics carried out leak tests and cleaning trials in its in-house test laboratory. The results were used to evaluate the product design and the intended use of the Samplistick.

Prototypes

For the early development phase, BARLOG Plastics manufactured a high-quality prototype mould made of aluminium. The components produced from this mould were used to carry out comprehensive functional and leak-tightness tests.

The prototypes made it possible to test the product under realistic conditions and gain insights for further optimisation before series production began.

Small-batch production and assembly

To date, BARLOG Plastics has produced, assembled and delivered around 8,000 Samplisticks to the customer as part of its small-batch production programme.

Conclusion

The customer was very satisfied with the appearance, feel and functionality of the prototypes. The selected material met the technical requirements of the application and proved suitable for subsequent series production.

The project demonstrates how BARLOG Plastics can support customers in the rapid, reliable and cost-effective launch of new products through its expertise in materials, development services, and prototype and small-batch production. The combination of material selection, simulation, mould design, laboratory testing and manufacturing enabled the project to be implemented in a targeted manner, from the initial idea through to market readiness.

A material based on recycled PET was used for the project; its properties were evaluated during development and qualified for the application.

The successful implementation of the ‘Samplistick’ project highlights BARLOG Plastics’ expertise in supporting start-ups and innovative product developments. Through the combination of materials know-how, development expertise and manufacturing competence, products can be efficiently supported from the initial idea through to series production.