Evolabel, marketleader in industrial Print & Apply systems, collaborated with QDP on the development of the SoftPad: an innovative 3D-printed applicator pad designed for precise labeling on uneven and curved surfaces. The SoftPad, produced using Carbon DLS™ technology, offers a unique combination of flexibility, precision, and durability — enabling Evolabel to serve new application areas without compromising speed and reliability.
Background: Rising Demands in Labeling Technology
With the ongoing automation in packaging and logistics processes, labeling systems are increasingly confronted with challenges such as curved, soft or textured surfaces. Evolabel identified a growing demand for solutions that can handle these, without sacrificing performance. Existing foam or rubber pads often failed to meet mechanical consistency or longevity requirements in industrial applications.
“SoftPad is used for vacuum application of labels. The challenge was to apply labels on uneven surfaces with high repeatability.”
The solution: 3D printed SoftPad
Evolabel engaged QDP as an additive manufacturing partner to jointly develop a custom solution. The result was a two-part construction:
- Rigid part: Secures the SoftPad to the machine and creates the vacuum to hold the label.
- Soft part: Adapts to the shape of the product and supports the vacuum mechanism for optimal label adhesion.
The complex lattice structure of the soft component was designed and optimized with Carbon’s Design Engine™ software, allowing the pad to bend smoothly while remaining robust during intensive use.
“Our collaboration with QDP was highly productive. Their expertise was crucial in creating a functional, high-quality product.”
Material Selection and Validation
The choice of Carbon DLS™ materials was made in partnership with QDP. Evolabel set high requirements: flexibility, wear resistance, durability, and vacuum integrity all had to be guaranteed. After extensive tests, both in the lab and on-site with customers, EPU 41 was chosen for the elastic parts and EPX 82 for the rigid components.
Hard Material
EPX 82
High-quality material with high strength, impact resistance and heat resistance for demanding applications.
Elastomer
EPU 41
Production-quality elastomer particularly suitable for lattice structures where high resilience is required
“We are impressed by the precision of the printer and the material properties. Carbon’s technology opens new possibilities for industrial applications.”
Design and Production Process
The process started with material tests on friction and label adhesion. Next, a joining technique was sought that could effectively combine the soft and hard parts. QDP’s experience in both injection molding and 3D printing significantly accelerated the design and optimization process. After a successful validation phase, production could be scaled up directly, without the long lead times of traditional mold-making.
“Thanks to QDP, we were able to go from design to production within a month, while traditional processes would have taken months.”
Results and Expectations
The SoftPad has now been successfully tested on various surfaces such as steel pipes, metal blocks, sealed packages and plastic containers. Customer feedback at trade fairs and test locations has been very positive. The SoftPad will be added to Evolabel’s standard product range in the second quarter of 2025.
“The SoftPad elevates our label performance to a higher level and will help us reach new customers and serve existing customers better.”
SoftPad installation in use at customer:
Impact and Benefits
In addition to improved performance, the SoftPad also offers benefits in terms of reliability and cost reduction:
- Less downtime and failures
- Better label placement
- Less loss of quality during data processing
- Higher customer satisfaction
“The surface can be adapted to the application. It is more consistent and reproducible than foam-based products.”
Collaboration with QDP
The collaboration with QDP was experienced as practical and efficient.
“Very pleasant to work with. A lot of knowledge, fast and easy communication, good support.”
This collaboration opens up possibilities for further innovation and expansion of components within the Evolabel portfolio.