Design for Ergonomics & Manufacturing
Year
2025
Skills
3D Prototype Testing
Ergonomics Study
Bottle Engineering & Manufacturing
In partnership with Altium Packaging® and Studio PKG™ to create a consumer multi-purpose dairy bottle. The 48oz bottle for Ninth Avenue Foods must function both as a creamer, and cold brew container.
This project encapsulates a fast paced and user centered design for manufacturability withing the HDPE blow molding industry. The product maximizes manufacturing efficiency throughout its lifetime, ergonomics, and plastic sustainability.
Objective
Ninth Avenue is looking for a 48oz bottle with 5% headspace that maximizes production ease, efficiency and user ergonomics.
Objective
Ninth Avenue is looking for a 48oz bottle with 5% headspace that maximizes production ease, efficiency and user ergonomics.
Objective
Ninth Avenue is looking for a 48oz multipurpose bottle with 5% headspace that maximizes production ease, efficiency and user ergonomics.
Manufacturing concerns
Unchanged Footprint
Use as a cold brew and creamer
Design for durability
Manufacturing concerns
Unchanged Footprint
Use as a cold brew and creamer
Design for durability
Manufacturing concerns
Unchanged Footprint
Use as a cold brew and creamer
Design for durability
Putting the user first
Competing products of both the creamer and cold brew category were tested using a diverse audience. User actions and pain points were recorded from pour to shelf.
Putting the user first
Competing products of both the creamer and cold brew category were tested using a diverse audience. User actions and pain points were recorded from pour to shelf.
Understanding the market
Store walks and competitor assessments were made in store as well as with users to understand competitors store presence, shelf availability, and key design trends within the segment.
Understanding the market
Store walks and competitor assessments were made in store as well as with users to understand competitors store presence, shelf availability, and key design trends within the segment.
Using research to fuel design decisions
Using research to fuel design decisions
Design considerations & constraints
Understanding HDPE blow molding processes.
Designing around manufacturability.
Developing a relationship with engineers and craftsmen.
Design considerations & constraints
Understanding HDPE blow molding processes.
Designing around manufacturability.
Developing a relationship with engineers and craftsmen.
Design considerations & constraints
Understanding HDPE blow molding processes.
Designing around manufacturability.
Developing a relationship with engineers and craftsmen.
Concept delivery
Three concepts were presented to Ninth Avenue with ergonomic reasoning behind each. All of which share relatively the same engineering specifications, only differing in design and performance.
Concept delivery
Three concepts were presented to Ninth Avenue with ergonomic reasoning behind each. All of which share relatively the same engineering specifications, only differing in design and performance.
Prototyping with a purpose
Several 3D printed resin models were printed throughout the concept's four major iterations to understand form as a trade off of manufacturing constraints. Wall thickness and material dynamics were considering in matching the feel of a high density polyethylene bottle.
Prototyping with a purpose
Several 3D printed resin models were printed throughout the concept's four major iterations to understand form as a trade off of manufacturing constraints. Wall thickness and material dynamics were considering in matching the feel of a high density polyethylene bottle.
Takeaways
The Ninth Avenue multipurpose bottle is currently in production on the west coast of the United States. It will be sold nationally. The brand remains anonymous until it reaches store shelves in January 2026.
This project currently stands as the record for fastest custom packaging solution to reach commercialization in Altium Packaging's company history.
Takeaways
The Ninth Avenue multipurpose bottle is currently in production on the west coast of the United States. It will be sold nationally. The brand remains anonymous until it reaches store shelves in January 2026.
This project currently stands as the record for fastest custom packaging solution to reach commercialization in Altium Packaging's company history.
Previous Project
