Canadian Innovation: This case study demonstrates how rapid prototyping transforms product development, enabling 20+ design iterations in just 2 weeks to solve real-world problems affecting millions of consumers daily.
At Forge Labs, we pride ourselves on accelerating product development, making it possible for new ideas to be iterated and taken to market faster than ever. In 2017, design company One Twenty Three West came to us with a challenging deadline: help them produce CAD files and physical prototypes for their redesign of the classic Tim Hortons lid in just a couple of weeks.
This case study showcases the power of rapid prototyping in solving real-world design challenges. With over 2 billion Tim Hortons lids produced annually, even small improvements have massive environmental and user experience impacts across Canada.
SLA-printed prototypes showcasing multiple design iterations of the Tim Hortons lid redesign
The Design Challenge
The original Tim Hortons lids suffered from several critical problems that affected millions of Canadian coffee drinkers daily:
Original Lid Problems
- Leakage Issues: Poor sealing caused frequent spills during transport
- Sharp Edges: Uncomfortable drinking experience with potential for cuts
- Environmental Impact: Non-recyclable material contributed to waste
- Brand Experience: Poor functionality reflected negatively on the Tim Hortons brand
- Scale Impact: With 2 billion units annually, small problems became massive issues
Design Requirements
The redesign needed to address these fundamental issues while maintaining manufacturing feasibility and brand identity:
- Spill Prevention: Effective seal and spill management features
- User Comfort: Smooth, comfortable drinking surface
- Environmental Responsibility: Recyclable polypropylene material
- Canadian Identity: Incorporation of recognizable Canadian symbols
- Manufacturing Viability: Design compatible with high-volume injection molding
- Cost Effectiveness: Competitive production costs at massive scale
Rapid Prototyping Design Process
Collaborative Development Approach
Over the span of just two weeks, our design team worked closely with One Twenty Three West to translate concept art into functional 3D models. This collaborative process involved multiple stakeholders and rapid iteration cycles.
Initial concept renders showcasing the maple leaf spill reservoir and improved ergonomics
Iteration Methodology
From provided sketches and schematics, we produced more than 20 unique CAD files, renders, and 3D printed models for review. This rapid iteration approach enabled:
- Daily Design Reviews: Quick assessment of each iteration's performance
- Physical Testing: Real-world functionality testing with actual coffee cups
- Stakeholder Feedback: Rapid incorporation of client and user feedback
- Design Optimization: Continuous refinement of features and aesthetics
- Manufacturing Validation: Early assessment of production feasibility
High-fidelity SLA prototypes demonstrating the evolution from initial concepts to final design
The Maple Leaf Innovation
After 20+ iterations, the design team converged on the breakthrough maple leaf concept. This iconic solution serves multiple functional and branding purposes:
Functional Benefits
- Spill Reservoir: Maple leaf shape catches and contains spills
- Improved Sealing: Enhanced lip contact area
- Ergonomic Design: Comfortable drinking angle
- Visual Indicator: Clear drinking position guidance
Brand Identity
- Canadian Symbol: Instantly recognizable maple leaf
- Tim Hortons Heritage: Reinforces Canadian brand identity
- Distinctive Design: Unique visual differentiation
- Emotional Connection: Pride in Canadian innovation
Technology Selection: Why SLA?
For this project, Stereolithography (SLA) in Accura Xtreme White was selected, running on our 3D Systems ProJet 6000 HD industrial printers. This technology choice was critical to project success.
Forge Labs SLA laboratory featuring our fleet of 3D Systems ProJet 6000 HD industrial printers
SLA Advantages for Product Development
| Factor | SLA Advantage | Project Impact |
|---|---|---|
| Speed | Ultra-fast laser scanning | Rapid iteration cycles |
| Thin Features | 0.8mm walls achievable | Realistic lid thickness |
| Resolution | 100-micron precision | Fine detail reproduction |
| Surface Finish | Smooth, injection-molded appearance | Realistic prototype feel |
| Cost | Low material usage | Multiple iterations feasible |
Speed Comparison Analysis
One of the primary reasons we recommended SLA for this prototyping project was speed. The laser-based resin printing process uses high-speed galvanometers instead of slow mechanical gantries, enabling rapid production.
Production Time Comparison
SLA (ProJet 6000 HD)
- • Print time: 1 hour 24 minutes
- • Layer height: 100 microns
- • High-speed laser scanning
- • Minimal mechanical movement
FDM (Prusa i3)
- • Print time: 3 hours 4 minutes
- • Layer height: 100 microns
- • Mechanical gantry movement
- • Sequential material deposition
Result: SLA achieved 2.2x faster production, enabling same-day iteration cycles
Material Selection and Properties
Accura Xtreme White Advantages
For the prototypes, Accura Xtreme White was chosen as the optimal resin, providing properties that closely mimicked the intended production material:
- Visual Similarity: Bright white color matching injection-molded appearance
- Mechanical Properties: Durability and toughness comparable to polypropylene
- Processing Speed: Fast curing for high throughput production
- Detail Resolution: Excellent fidelity for fine features
- Surface Quality: Superior sidewall characteristics
- Post-Processing: Accepts UV-resistant clear coating
Thin Wall Manufacturing Challenge
With a wall thickness of only 0.8mm, the prototypes presented significant manufacturing challenges that SLA uniquely addressed:
Alternative Technology Limitations
- FDM: Thin walls collapse or exhibit poor strength
- SLS: Powder support may damage delicate features
- PolyJet: High cost for multiple iterations
- Traditional: Machining thin walls impossible
SLA Solutions
- Structural Integrity: Excellent durability at thin dimensions
- Flexibility: Appropriate flex for lid functionality
- Precision: ±0.2mm tolerances enable proper fit testing
- Functionality: Parts suitable for actual testing
Support Structure Optimization
Support structure design and removal significantly impact both production speed and prototype quality. Our industrial SLA process offers substantial advantages in this critical area.
Support comparison: 3D Systems small touchpoints (left) versus Formlabs large supports (right)
Industrial vs. Desktop SLA Comparison
| Aspect | 3D Systems (Top-Down) | Desktop SLA (Bottom-Up) |
|---|---|---|
| Support Touchpoints | Small, delicate contact points | Large, thick attachment points |
| Surface Quality | Minimal surface artifacts | Significant marks requiring finishing |
| Removal Time | Quick, easy removal | Time-intensive post-processing |
| Material Usage | 5% support density | Higher support material usage |
Support Design Strategy
Our industrial SLA process prints below the resin surface, allowing the viscous resin itself to provide partial support. This enables:
- Minimal Support Structures: Fine touchpoints with negligible surface impact
- Cost Efficiency: Low material usage reduces part cost
- Time Savings: Rapid support removal and minimal finishing
- Surface Quality: No distinguishable 'A' or 'B' surfaces
- Design Freedom: Complex geometries without support constraints
Post-Processing and Quality Control
Finishing Workflow
Professional post-processing ensures prototypes meet presentation and testing requirements:
- Support Removal: Careful removal of delicate support touchpoints
- Surface Preparation: Light sanding to eliminate any support artifacts
- Quality Inspection: Dimensional verification and visual assessment
- UV Protection: Clear coat application to prevent yellowing
- Functional Testing: Fit testing with actual coffee cups
Quality Validation Process
Each prototype underwent rigorous testing to validate design performance:
Testing Protocol
- Dimensional Accuracy: Measurement against CAD specifications
- Fit Testing: Physical testing with standard Tim Hortons cups
- Spill Performance: Evaluation of spillage prevention effectiveness
- User Comfort: Ergonomic assessment of drinking experience
- Durability Testing: Mechanical stress evaluation
- Visual Assessment: Appearance and brand alignment review
Project Impact and Outcomes
Successful Market Implementation
Today, the final lid design, now produced in recyclable polypropylene, can be found on every Tim Hortons coffee cup across Canada. The project's success demonstrates the power of rapid prototyping in solving real-world problems.
Environmental Impact
- 2 billion annual units now recyclable
- Reduced waste through improved functionality
- Sustainable materials throughout production
- Circular economy design principles
User Experience
- Eliminated spillage through maple leaf reservoir
- Improved comfort with smooth drinking surface
- Enhanced brand pride through Canadian symbolism
- Consistent quality across all locations
Rapid Prototyping ROI
The project demonstrated exceptional return on investment through rapid prototyping methodology:
- Time Savings: 2-week development vs. traditional 2-3 month timeline
- Cost Efficiency: Multiple iterations within budget constraints
- Risk Reduction: Early validation prevented costly manufacturing errors
- Market Speed: Faster time-to-market captured competitive advantage
- Quality Assurance: Physical testing ensured optimal final design
Lessons for Product Development
Best Practices for Rapid Prototyping
This project highlighted several critical success factors for rapid prototyping projects:
Key Success Factors
- Technology Selection: Match printing technology to specific requirements
- Iteration Planning: Build multiple test cycles into project timeline
- Stakeholder Engagement: Include all decision-makers in review process
- Testing Integration: Plan for functional testing throughout development
- Manufacturing Consideration: Design with production constraints in mind
- Quality Standards: Maintain consistent finishing and inspection protocols
Technology Recommendation Framework
When selecting 3D printing technology for product development, consider these factors:
| Requirement | Recommended Technology | Key Benefits |
|---|---|---|
| Thin Features (< 1mm) | SLA | Precision, structural integrity |
| Speed Priority | SLA (Industrial) | Laser scanning, minimal supports |
| Large Parts | FDM | Build volume, cost efficiency |
| Functional Testing | SLS/SLA | Material properties, durability |
Ready to accelerate your product development? Our rapid prototyping services can help you iterate faster and bring better products to market. Contact us at sales@forgelabs.com to discuss your project requirements and timeline.
Conclusion: The Power of Rapid Prototyping
The Tim Hortons lid redesign case study demonstrates how rapid prototyping transforms product development from a lengthy, risky process into an agile, validation-driven workflow. By enabling 20+ design iterations in just two weeks, we helped solve a problem affecting millions of Canadians while creating an iconic piece of Canadian design.
This project showcases the intersection of advanced manufacturing technology, thoughtful design process, and real-world problem solving. The resulting maple leaf lid stands as a testament to Canadian innovation and the power of rapid iteration in creating products that truly serve users' needs.
Project Success Metrics
- 2-week development timeline achieved
- 20+ design iterations completed
- Zero manufacturing delays from design issues
- 2 billion annual units now recyclable
- Spillage problems completely eliminated
- User comfort significantly improved
- Strong Canadian brand identity reinforced
- Successful nationwide implementation
The success of this project continues to inspire our approach to rapid prototyping, demonstrating that with the right technology, process, and collaboration, even the most ambitious timelines can be achieved while delivering exceptional results.