BMT and Dassault Systèmes link simulation with bottle trials

Blow Moulding Technologies (BMT) will demonstrate how packaging manufacturers can accelerate bottle development, reduce trial-and-error testing and shorten time to market by integrating simulation, process measurement and physical validation. The presentation will take place at Pack Expo International 2026, held at McCormick Place in Chicago from 18 to 21 October. BMT combines specialist stretch blow moulding expertise with virtual modelling and real-world validation to support analysis of material behaviour, forming processes and finished bottle performance. Its capabilities include Blowscan and Thermoscan, which provide process measurements and data intended to support development decisions. The approach is designed to identify promising bottle geometries before manufacturers commit resources to tooling, prototypes or production-scale trials.

"A physical pilot trial can take up to eight weeks and cost around £20,000 for a single bottle geometry," commented David McKelvey, Ph.D., Head of Product at Blow Moulding Technologies. "Using simulation, we can explore dozens of design variations in less than a week, allowing manufacturers to identify the most promising solution before investing in tooling or physical testing. The result is a faster, more efficient development process with greater confidence that the final trial will succeed."

Predictive models within one digital workflow

As part of the Pack Expo Innovation Stage programme, McKelvey will join Alex Byrne, MODSIM Industry Process Consultant at Dassault Systèmes, to present "Predictive Models for Smarter Results: One Digital Workflow for Blow Molding". The session is scheduled for Monday, 19 October 2026, from 11:00 to 11:30 a.m. at the Innovation Stage in the North Hall.

The presentation will examine how manufacturers can move beyond sequential design processes, in which problems may only become apparent late in development. Such delays can lead to repeated tooling iterations, postponed validation and limited opportunities to investigate alternative designs. McKelvey and Byrne will demonstrate an integrated, physics-based approach that connects material behaviour, the stretch blow moulding process and structural performance within a single digital workflow.

The collaboration combines BMT's expertise in stretch blow moulding and material characterisation with Dassault Systèmes' finite element analysis (FEA) simulation and 3Dexperience platform. By linking forming simulations with performance analysis and physical testing, manufacturers can examine how choices concerning materials and processing parameters affect the performance of the finished bottle.

Connecting virtual development with physical validation

Combining stages that have traditionally been handled separately allows manufacturers to make important design decisions earlier. Material selection, processing conditions and structural performance can be assessed together before investment in physical prototypes, tooling or full-scale production trials.

According to BMT, the workflow can reduce development iterations and costs, shorten development cycles and provide a broader basis for design decisions. It can also support lightweighting projects and the use of higher levels of post-consumer recycled (PCR) material, applications in which reliable prediction of material behaviour is particularly important.

During Pack Expo, BMT will show how simulation, measurement and physical validation can support the transition from virtual bottle design to production. The company will exhibit with Dassault Systèmes at stand N-5972. David McKelvey and Jude Cameron, Head of Commercial at BMT, will be available to discuss the use of simulation and process data in bottle development from the concept stage through to production.