What is SMART prototyping and how does it help you work ‘smarter’?

Our Belfast‑based team specialises in data‑driven tools for PET bottle development. We help fast‑moving consumer goods and beverage companies turn lab concepts into tangible prototypes in just five days.
BMT’s approach:

We create a digital version of the bottle and run virtual tests to spot any issues - from how it forms into the mould and how the bottle performs during use.

In parallel with simulation, we use high‑precision 3D printing to design and produce custom moulds. This builds the exact bottle shape in a durable printed material, allowing us to blow prototype bottles quickly and move into testing without delay.

 These early prototypes are blown using our stretch‑blow moulding (SBM) solution, BLOWSCAN, which forms bottles under production‑like conditions and captures real‑time performance data. From here, we create the final bottles for physical validation, ensuring the design works in real‑world use before full-scale production.

Together, these stages give packaging manufacturers the clarity, data and confidence to make better decisions earlier, helping to work smarter by reducing risk, accelerating development and cutting wasted effort. 

We have partnered with Packamama using our SMART prototyping approach.

Packamama, the London-based wine bottle innovator, worked with BMT to bring these forward-thinking bottle designs from concept to reality.

Applying BMT’s technical expertise and SMART prototyping approach, we developed functional prototypes in just five days to help Packamama evaluate and refine their bottle designs.

As a result, Packamama was able to accelerate their product development while supporting their mission of creating climate-friendly bottles and lowering the carbon footprint of wine packaging.

Celebrating Jude Cameron: Women in Business NI Finalist

We are incredibly proud to share that our own Jude Cameron was named a finalist in the Women in Business NI Young Businesswoman of the Year Award.

The awards ceremony took place this week, celebrating some of the most talented and driven young businesswomen across Northern Ireland. To be recognised among that group is no small achievement, and it's a testament to the hard work, dedication, and expertise that Jude brings to the team here at BMT every single day.

Digital Twin Adoption Accelerator

BMT and Vikela are working together through the Digital Twin Adoption Accelerator (Digital Catapult) to advance the design and manufacture of lightweight body armour.

By applying predictive digital twin modelling, we aim to optimise performance, reduce development risk and validate designs before committing to production.

Over the coming months, we’ll be working closely with the Centre’s expert technologists and leading industry mentors to build, test, and refine our digital twin solution, improving UK industrial supply chain resilience.

A huge thank you to the Centre for this incredible opportunity. We can’t wait to collaborate, learn, and push the boundaries of what’s possible.

Find out more about the UK Digital Twin Centre here: https://www.digicatapult.org.uk/programmes/programme/uk-digital-twin-centre/?utm_source=Website&utm_medium=partner_social&utm_campaign=digital_twin_adoption_accelerator_cohort_comms_pack

Beyond Trial and Error: BMT at the Blow Moulding Conference 2025, Brussels

This week, BMT's Jude Cameron and David McKelvey attended the Blow Moulding Conference in Brussels.

David took to the stage to deliver his talk:

“Beyond Trial and Error: A Data-Driven Approach to Sustainable Packaging”

Showcasing BMT's Measure–Digitise–Execute approach to stretch blow moulding process optimisation. By combining unique measurement systems, AI-driven simulation, and streamlined execution, we help manufacturers move away from costly trial and error towards confident, data-driven decisions.

The response from the audience was fantastic, with strong interest in how BMT's approach can reduce material waste, cut costs, and accelerate time to market.

Want to learn more about how BMT can support your packaging goals? Get in touch — we'd love to hear from you.

A Great Week at drinktec 2025

drinktec 2025 was an excellent event for BMT, filled with innovation, valuable conversations, and strong industry engagement.

We showcased our SMART prototyping platform, highlighting how FMCG brands can accelerate bottle development through virtual simulation, 3D-printed moulds, and lab-scale testing. There was clear interest in how data-driven approaches can reduce risk, support lightweighting, and improve performance.

We connected with a wide range of professionals from innovators and converters to brand owners and machine manufacturers, many of whom are focused on bringing greater efficiency and insight into blow moulding processes. Our technologies, including THERMOSCAN, THERMOSCAN XL, and BLOWSCAN, sparked particularly strong discussions around production optimisation.

Most importantly, it was fantastic to reconnect with clients, meet new partners, and be part of the energy driving innovation across the PET packaging industry.

Thank you to everyone who visited our stand, we look forward to continuing the conversation.

We’ve released a new render showing how BLOWSCAN works — our lab-based stretch blow moulding machine that enables detailed analysis of PET and bio-based materials.

Watch the render here: BLOWSCAN - Render

BLOWSCAN helps packaging innovators:

• Test and validate PET & bio-resin preforms at lab scale

• Optimise bottle design before full production

• Troubleshoot defects like haze, pearlescence, and variation in bottle performance

For the full story, visit our product page: Explore BLOWSCAN

Dr Josh Turner, Head of Materials Characterisation, and Dr Jude Cameron, Project Lead, will present at PETnology Europe 2025 on the BMT Way: Smarter Solutions for Sustainable Packaging.

Our approach — Measure, Digitise, Execute — moves beyond the packaging industry’s reliance on trial-and-error, empowering partners to make data-driven decisions. By combining:

• Cutting-edge simulation

• AI-driven insights

• Hands-on engineering expertise

We help packaging innovators to:

• Reduce material waste through efficient virtual prototyping

• Lower the risks of adopting new, sustainable materials

• Accelerate product development for future-ready packaging

We’re incredibly proud that Dr. Ross Blair received the Best Presentation Award at this year’s NAFEMS World Congress in Austria, representing BMT in the global spotlight.

His award-winning presentation,
“Measure, Digitise, Execute: Streamlining Sustainable Packaging Design,”
was recognised among top leaders in engineering simulation and sustainable product design.

This prestigious recognition is a testament to the dedication and innovation of our full team:

Dr. Ross Blair, Dr. Dimitris Papadimitrakis, Reece Armstrong, Alexander McKee and Professor Gary Menary

Our team is pushing the boundaries of sustainable packaging by applying a unique Measure, Digitise, Execute methodology. Using advanced simulation technology, we help businesses:

• Minimise packaging waste

• Improve performance and durability

• Meet sustainability goals through smart design

This achievement reflects our mission to deliver data-driven, eco-conscious solutions in packaging and manufacturing.

Our article in the May edition of PETplanet insider dives into how digital simulation and advanced material modelling are transforming preform and bottle development.
From virtual validation to physical formation, our Smart Prototyping approach helps teams streamline design, reduce waste, and move faster with confidence.

Measure. Digitise. Execute.

That’s how we’re supporting more sustainable PET packaging, from prototype to production.

Read the full article here
Catch up on the full BMT Bottle Series

Our Head of Material Characterisation, Dr Josh Turner, will be in Amsterdam on 1–2 April for the Plastics Recycling Show Europe (PRSE).

If you’re aiming to:

• Fast-track rPET adoption in packaging

• Reduce defects and production issues

• Maintain clarity and quality in recycled plastics

Josh is the expert you’ll want to speak with.

Still relying on trial-and-error for packaging design?

In PETplanet Insider, we showcased how Smart Prototyping with BLOWSCAN—combined with 3D printed moulds—lets converters move confidently from virtual validation to real-world results.

By testing and refining bottle designs before full-scale production, leading packaging teams are:

• Streamlining product development

• Reducing material waste

• Lowering production costs

• Accelerating packaging innovation

Don’t guess. Validate smarter with BLOWSCAN.

Find out more about our SMART Prototyping process.

The transition from virgin PET to rPET in stretch-blow moulding is far from plug-and-play. Recycled PET often exhibits lower intrinsic viscosity, increased variability in crystallinity, and reduced strain hardening. These changes significantly affect preform stretchability, wall distribution, and bottle clarity.

Manufacturers must adapt their process settings to accommodate:

• Blow-moulding temperatures: rPET typically requires tighter control due to its thermal sensitivity.

• Stretch ratios: The strain-hardening behaviour of rPET lags behind virgin PET, which can cause early pearlescence if not properly managed.

• Residence time & drying: rPET is more hygroscopic and must be thoroughly dried to prevent hydrolytic degradation during processing.

Tools like BLOWSCAN and Digital Image Correlation (DIC) can quantify these differences and help optimise the process window for rPET materials — ensuring product performance is maintained despite material variability.

Read our article here.

Dr Ross Blair, our Head of Simulation, presented at the Smart Sustainable Plastic Packaging Challenge Celebration Event, hosted by Innovate UK and UKRI
Ross shared insights on how digital innovation and simulation at BMT are driving smarter, more sustainable packaging solutions.

Beyond the Surface: Optimising rPET Heating

In our article in PETplanet Insider, we look at why surface temperature isn’t enough — and how getting the preform heating profile right is key to consistent bottle quality. THERMOSCAN measures both internal and external temperatures, giving a full picture of how each preform responds to heat. This helps improve oven setup, reduce defects, and manage rPET variability with more confidence.

Read the article: Beyond the Surface: Mastering Preform Heating for rPET Success

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