The Rise of 3D Printing in the Printing & Packaging World

By Shannon Polaski-Buchholz, Flexo Finders & Print Pack Careers

In the past decade, additive manufacturing (3D printing) has expanded beyond its early applications in aerospace, medical, and prototyping. Today, the printing and packaging industries are discovering practical ways to use 3D printing to improve efficiency, innovation, and sustainability.

This blog explores how 3D printing is influencing packaging, what’s possible today, and what’s coming next.

Why 3D Printing Matters to Printing & Packaging

1. Faster Prototyping & Iteration

Traditionally, creating new packaging molds or tooling meant long lead times and multiple vendors. With 3D printing, designs can be brought to life quickly, tested, and refined in-house — cutting time between concept and production dramatically.

This allows companies to:

• Validate fit and form before investing in tooling

• Test complex shapes and undercuts

• Shorten time to market

2. On-Demand Spare Parts & Tooling

Downtime in packaging operations is expensive. 3D printing enables teams to produce spare parts, fixtures, or jigs on demand, reducing delays and reliance on external suppliers.

Examples include:

• Press or finishing machine components

• Mold inserts or small tooling elements

• Custom alignment jigs or guides

3. Lightweight, Waste-Reducing Design

Because additive manufacturing builds layer by layer, it eliminates much of the waste from traditional machining. It also allows for lightweight designs that maintain strength while using less material — a major win for sustainability and shipping costs.

4. Customization & Personalization

In today’s market, custom packaging sells. 3D printing enables brands to easily produce unique textures, embossing, limited editions, or personalized designs without the need for new tooling or large setup costs.

This flexibility helps brands stand out and connect emotionally with consumers.

5. Sustainability & Localized Production

Sustainability continues to be a major driver for innovation in packaging. 3D printing helps reduce waste, enable localized production, and support the use of eco-friendly materials like bioplastics or recycled composites.

Printing closer to end markets also reduces transportation emissions and inventory storage needs.

Challenges to Consider

While promising, 3D printing isn’t replacing traditional packaging production just yet. Some challenges include:

• Speed & scale: High-volume runs remain faster with conventional methods.

• Material limits: Not all packaging materials are 3D-printable today.

• Regulatory standards: Food and medical packaging requires strict compliance.

• Equipment costs: Industrial-grade printers and maintenance represent an investment.

How Printing & Packaging Firms Can Get Started

1. Start small. Pilot additive manufacturing on tooling, fixtures, or short-run projects.

2. Partner first. Work with a 3D printing service provider before investing in-house.

3. Train your team. Encourage learning in CAD design and material science.

4. Integrate strategically. Use additive manufacturing to complement, not replace, traditional methods.

The Future of 3D Printing in Packaging

Expect continued innovation in:

• Multi-material printing for flexible and rigid components

• Hybrid additive + molding techniques

• Smart packaging with sensors and embedded electronics

• Compostable and bio-based materials for sustainability

• Faster production systems that make additive viable for larger runs

In Conclusion

3D printing is no longer just a buzzword — it’s becoming a powerful tool for the next generation of packaging innovation. Companies that explore it now will gain a competitive edge in speed, creativity, and sustainability.

If your company is considering integrating 3D printing into packaging or wants to connect with skilled professionals experienced in both printing and additive technologies, reach out to our teams today!

www.printpackcareers.com | www.flexofinders.com