Design Optimization and Weight Reduction of 500 mL CSD PET Bottle through FEM Simulations

Simulation description of a poly(ethylene terephthalate) bottle, blowing through the injection stretch blow molding process, using computer aided engineering softwares and analysis by finite elements method in order to better fit the bottle project using this material and weight reduction. The work was conducted from existing preforms and focused on the design process of the bottles, approach in which the available literature is scarce or nonexistent. The design of a bottle was executed, applied and validated through parametric computer aided design software and finite elements method analysis, allowing the simulation of the blowing process from data input to the process variables listed in the available literature. Using this approach, we simulate the blowing process and the mechanical demands related to the application with the aim of assessing the efficiency of packaging design and enable an efficient and correct sizing of the bottles. The data obtained in simulations were verified by the fabrication of prototypes using the same material, preform and process data considered in the virtual environment. The results indicate the feasibility of producing 500 mL bottles for carbonated soft drinks from 18 g preforms, with a reduction of up to 21% on weight of the packaging, keeping the standard bottle finish PCO-1810-28 mm.