How 3D printing helps the packaging industry reduce waste and innovate sustainably

As sustainability demands increase, the packaging industry finds itself at a crossroads. With most consumers now saying they prefer products with environmentally friendly packaging, and tightening regulations across Europe and beyond, companies must rethink not only materials, but also how they design and produce packaging in the first place.

That’s where 3D printing steps in - not only as a prototyping tool, but as a powerful enabler of leaner, more agile, and more sustainable packaging operations.

Facing sustainability challenges head-on

From single-use plastics to inefficient supply chains, packaging manufacturers are under pressure to evolve. Traditional methods like injection molding for prototypes can be time-consuming, expensive, and wasteful. Design changes often require new tooling, resulting in discarded materials and long delays.

At the same time, global supply chain disruptions and transportation-related emissions are pushing brands to consider localized, more responsive manufacturing strategies. All of this while staying compliant with increasing demands for recyclability and minimal material use.

Packaging companies need smarter tools - and fast.

3D printing: A flexible tool for sustainable innovation

UltiMaker’s 3D printing solutions are helping packaging manufacturers respond to these challenges in three key ways:

1. Faster, less wasteful prototyping

With 3D printing, packaging teams can quickly produce multiple design iterations without the need for costly and wasteful molds. This means better designs - faster, without mountains of waste.

Need to test a new bottle cap or carton closure? Instead of waiting weeks, engineers can print, test, and refine prototypes in a single day. That accelerates time to market while cutting material waste drastically.

2. Local, on-demand production

Rather than relying on centralized suppliers and long lead times, packaging companies are increasingly adopting distributed manufacturing models. With UltiMaker printers on-site, teams can produce low-volume tools, jigs, and replacement parts on demand, reducing shipping-related emissions and improving operational resilience.

This local-first mindset is not only more sustainable, it also gives teams greater control and flexibility in their development cycles.

3. Smarter use of sustainable materials

3D printing opens up the possibility to experiment with biodegradable and recyclable materials in a low-risk environment. Packaging designers can iterate with these materials more freely, fine-tuning form and function without the high upfront costs typically associated with tooling.

As new sustainable filaments become more available, 3D printing allows teams to integrate them more easily into the design process.

Using high-performance, wear-resistant materials in 3D printing can also result in decreased need for new spare parts. For example, UltiMaker’s Nylon CF Slide material is made for applications and machines that are under daily pressure. Additionally, Nylon CF Slide is a great PFAS-free option for POM.

Sustainable success, one print at a time

Companies across the packaging value chain are already using 3D printing to cut waste, localize production, and speed up sustainable innovation. From tooling for cardboard packaging lines to lightweight parts for plastic-free alternatives, additive manufacturing is reshaping what’s possible.

Learn more about how Heineken Sevilla has increased efficiency and ensured production continuity thanks to UltiMaker’s 3D printing ecosystem.

Leverage 3D printing for sustainable packaging production

The path to greener packaging doesn’t have to be complicated. With 3D printing, packaging companies can build agility, reduce their environmental footprint, and stay ahead of regulatory demands- all while accelerating innovation.

Want to learn how UltiMaker can support your sustainable packaging goals? Explore our solutions or get in touch to talk with our experts.