Design Process

THE PROCESS

Closure Design & Development

THE PROCESS

Closure Design &

Development

THE PROCESS

Closure Design & Development

Concept Design

Working from a set of requirements, UCL’s team of designers use the latest computer aided design software to quickly create 3D designs.

Presentations for customer review and critique are quickly drawn up so the design can be refined before prototyping.
 
Concept Design

Working from a set of requirements, UCL’s team of designers use the latest computer aided design software to quickly create 3D designs.

Presentations for customer review and critique are quickly drawn up so the design can be refined before prototyping.
 
Rapid Prototyping

In house rapid prototyping allows UCL’s designers to produce detailed 3D models of the designs quickly, often within hours.

This allows highly effective design critique and gives the customer insight into the design.

Developmental testing equipment is also produced using this methodology.
 

  • Can UCL offer rendered visual images of the product within conceptual stages?

    UCL can offer rendered visuals once the conceptual CAD has been completed.

  • What do UCL require to begin the concept stage?

    UCL require the most up-to-date finish drawing to allow the design team to understand exactly what the product requires to be compatible.

Rapid Prototyping

In house rapid prototyping allows UCL’s designers to produce detailed 3D models of the designs quickly, often within hours.

This allows highly effective design critique and gives the customer insight into the design.

Developmental testing equipment is also produced using this methodology.
 
Detailed Design

Working in conjunction with our specialist injection moulding partner z-moulds, the design is fully detailed through DFM review ahead of sample production via pilot tooling.

Simulation and analysis tools in combination with vast experience ensure the finest details are resolved before committing to tooling.
 

  • Do UCL offer a 3D print service?

    Rapid prototyping is a key stage in the UCL design process. It drastically has helped the development of projects and can show a clear representation to the customer of exactly how the product looks and performs.

  • What 3D printing system and software do UCL use?

    UCL have recently invested in the Form 3+ Low Force Stereolithography printer. This allows us to produce functional, high quality prototypes efficently. The modernised technology offers industry-leading accuracy and reliability.

  • Are UCL prototypes functional?

    The design team attempt to make all prototypes at least semi-functional, dependant of what is being tested. The printing facilities offer a range of resins that share properties similar to HDPE.

Detailed Design

Working in conjunction with our specialist injection moulding partner z-moulds, the design is fully detailed through DFM review ahead of sample production via pilot tooling.

Simulation and analysis tools in combination with vast experience ensure the finest details are resolved before committing to tooling.
 
Pilot Tooling
  
Carried out exclusively at z-moulds, the high precision pilot tooling allows for sample production entirely representative of final production samples. 

Only this way can we be sure samples suitable for an extensive testing and trialling process necessary before the closure is ready for commercial production. 
 

  • What CAD software is used to ensure the greatest design and finest details?

    The design team are experienced and professionally trained across a variety of computer aided design software and 3D design programs. SolidWorks being the most commonly used here at UCL.

Pilot Tooling
  
Carried out exclusively at z-moulds, the high precision pilot tooling allows for sample production entirely representative of final production samples. 

Only this way can we be sure samples suitable for an extensive testing and trialling process necessary before the closure is ready for commercial production. 
 
Iterative Testing

Full testing programs, including closure capping, are carried out in the PepsiCo Certified Laboratory. These programs give confirmation of a closures conformance to meet industry standards.

These tests also inform the evolution of the design to maximise the closures performance and optimise its efficiency.
 

  • Who are Z-Moulds?

    Z-Moulds are a partner of UCL that work very closely throughout all projects. They are one of the pioneers in the mould-making industry. They offer the highest level of Pilot Tools, Prototypes amd Tooling expert knowledge.

  • Where are Pilot Tools manufactured and Sample runs carried out?

    Z-Moulds are based in Dornbirn, Austria. All sample runs and tool making takes place in their state of the art facilities.

  • How long have UCL worked alongside Z-Moulds?

    UCL and z-moulds have been working together since 2010.

Iterative Testing

Full testing programs, including closure capping, are carried out in the PepsiCo Certified Laboratory. These programs give confirmation of a closures conformance to meet industry standards.

These tests also inform the evolution of the design to maximise the closures performance and optimise its efficiency.
 
Closure Trials

Pre-trial inspections are carried out at the capping plant to ensure everything is in place for a successful trial.

If necessary, change parts are manufactured and supplied for the line trial proper. Fully managed by UCL’s highly experienced field engineers, these trials confirm the closures readiness for commercial application.
 
Closure Trials

Pre-trial inspections are carried out at the capping plant to ensure everything is in place for a successful trial.

If necessary, change parts are manufactured and supplied for the line trial proper. Fully managed by UCL’s highly experienced field engineers, these trials confirm the closures readiness for commercial application.
 
Commercial Production

UCL, along with z-moulds, oversee the Acceptance Testing of each and every closure production system during their installation and start up. Ensuring the system is set-up for optimum operation and that closures conform to the necessary specifications. Full training, technical documentation and QC set-up is provided through each closure project to ensure a smooth start-up to commercial production.
 
Commercial Production

UCL, along with z-moulds, oversee the Acceptance Testing of each and every closure production system during their installation and start up. Ensuring the system is set-up for optimum operation and that closures conform to the necessary specifications. Full training, technical documentation and QC set-up is provided through each closure project to ensure a smooth start-up to commercial production.
 
Continued Support

Throughout commercial production, UCL’s in-field engineering services and support assistance from the technical centre is on hand to help ensure closures meet the highest standards of quality and consistency. Trouble shooting or system optimisation UCL has the expertise to ensure best in class production.
 
Continued Support

Throughout commercial production, UCL’s in-field engineering services and support assistance from the technical centre is on hand to help ensure closures meet the highest standards of quality and consistency. Trouble shooting or system optimisation UCL has the expertise to ensure best in class production.
 
Material Specialists

SCG 
DOW 
PTT 
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