Redesigning Canada's Coffee Lid: Tim Hortons Case Study in Rapid Prototyping and SLA 3D Printing

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:

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:

1. Daily Design Reviews: Quick assessment of each iteration's performance
2. Physical Testing: Real-world functionality testing with actual coffee cups
3. Stakeholder Feedback: Rapid incorporation of client and user feedback
4. Design Optimization: Continuous refinement of features and aesthetics
5. 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:

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

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.

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:

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

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:

1. Support Removal: Careful removal of delicate support touchpoints
2. Surface Preparation: Light sanding to eliminate any support artifacts
3. Quality Inspection: Dimensional verification and visual assessment
4. UV Protection: Clear coat application to prevent yellowing
5. Functional Testing: Fit testing with actual coffee cups

Quality Validation Process

Each prototype underwent rigorous testing to validate design performance:

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.

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:

Technology Recommendation Framework

When selecting 3D printing technology for product development, consider these factors:

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.

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.

Further Resources

• SLA Technology Guide
• Industrial vs Desktop SLA Comparison
• SLA Design Guidelines
• Complete Rapid Prototyping Guide