High-Performance Packaging: How Trivium Packaging Achieved 95% Cost Savings with Nylon CF Slide

In the high-speed world of metal packaging, even the smallest component can dictate the pace of an entire production line. For Trivium Packaging—a global leader in metal cans for everything from nutrition to aerosols—maintaining that pace means constantly looking for ways to reduce friction, both literally and operationally.

Traditionally, sourcing specialized machine parts meant navigating long lead times and high costs. But by leveraging the UltiMaker S Series and the new Nylon CF Expansion (Nylon CF Slide) material, Trivium has turned a "standard" replacement part into a masterclass in industrial efficiency.

The Challenge: The Anode Worm

The focus of Trivium’s recent innovation was the Anode Worm, a critical component that transfers can lids through a coating bath. This part must perform a complex balancing act: it conducts electricity to the lids for the coating process, yet it must remain wear-resistant, chemical-resistant, and moisture-resistant to survive the bath itself. Traditionally made from foam, these parts were prone to wear and required frequent replacement. Trivium needed a material that was:

• ESD Safe: To manage electrical conductivity without interference.
• Low Friction: To prevent damage to the lids during high-speed transfer.
• PFAS-Free: To comply with evolving environmental and safety regulations.
  
  

The Solution: 3D Printing with Nylon CF Slide

Using an UltiMaker S5 equipped with a CC 0.4 print core, the engineering team printed the Anode Worm using Nylon CF Slide. This carbon-fiber-reinforced material provided the structural rigidity and low-friction "slide" properties required for the coating line.

"For us, this is a classic example of the benefits of 3D printing. Lead times compared to outsourced parts are reduced significantly, while costs have been reduced by ninety-five percent and the performance of the part has improved quite a lot."

The results during industrial-scale testing surpassed the team's initial expectations in three key areas:

1. Precision and Geometry

Because the part was designed in-house, the team was able to optimize the grooves of the worm to fit the can lids more accurately than the legacy foam parts. This customization ensured a smoother transfer and fewer jams on the line.

2. Unexpected Material Benefits

During production tests, the team discovered a unique advantage: the coating material did not adhere to the Nylon CF Expansion. This "self-cleaning" property allowed Trivium to skip an entire cleaning cycle, maintaining consistent performance over longer periods. Furthermore, the low-friction nature of the material reduced wear on the surrounding metal machine parts."The material met all the requirements and even performed better than expected. During real production tests, we noticed the coating did not attract to the Nylon CF Slide material, so we could skip a cleaning cycle and performance stayed consistent."

3. Radical Cost and Lead Time Reduction

The shift from outsourced foam parts to in-house 3D printing resulted in a 95% reduction in costs. Beyond the financial savings, the lead time was slashed from weeks to hours, allowing the team to iterate on designs and implement improvements instantly.

A New Standard for Global Operations

What started as a single part test has now become a standard. Trivium has replaced all similar anode worms across their primary production lines with the 3D-printed version and is currently planning a rollout to other facilities worldwide.

"For us, this is a classic example of the benefits of 3D printing," says the team at Trivium. "It’s not just about making the part; it’s about making the job easier and more enjoyable while delivering massive value to the business."

By combining the reliability of the UltiMaker platform with high-performance composites like Nylon CF Expansion, Trivium Packaging isn't just maintaining their lines—they are accelerating them.