Eco-Sustainable, Low-Cost Packaging Design for 3D-Printed PETG Eyewear Lenses: Integrating Sustainable Packaging, Eco-Design Principles, and Financial Optimization through Simulation and Virtual Prototyping in SolidWorks.

Abstract

This paper presents an applied research proposal focused on designing an eco-sustainable, low-cost packaging system for 3D-printed optical lenses made of PETG material. It integrates sustainable packaging techniques (mono-materials, volume minimization, and recycled or biodegradable materials) with eco-design principles (design for disassembly, recyclability, and life-cycle extension) and advanced simulation tools in SolidWorks (CAD, Finite Element Analysis FEA, topology optimization, and the Sustainability module). The goal is to minimize environmental impact, ensure the mechanical protection of fragile geometries, enhance marketing value and, centrally, generate financial benefits by reducing unit costs of material, logistics, prototyping, and waste disposal outcomes that are especially relevant for Mexican SMEs in additive manufacturing. The research is classified as applied, simulation-based experimental, and mixed-methods in approach. It employs a systematic literature review under the PRISMA 2020 guidelines and an experimental design based on virtual prototypes (digital piloting) developed and evaluated in SolidWorks. The independent variables include sustainable packaging techniques, eco-design principles, and simulation parameters; the dependent variables span environmental sustainability, mechanical protection, commercial appeal, and techno-economic feasibility (unit cost, estimated ROI, and scalability). The results of the virtual piloting of Assembly are reported as follows: mass of 93.25 g, volume of 91,421.34 mm³, and surface area of 77,701.89 mm². These values demonstrate effective material minimization, consistent with reductions of ≥20% in carbon footprint and unit costs, estimated damage rates ≤5%, and economic feasibility for SME production batches validating the hypothesis of comprehensive improvement over conventional packaging.