Aplicação de prototipagem rápida na indústria cosmética

Application of rapid prototyping in the cosmetic industry

Rapid prototyping in the cosmetic industry

When we hear the word “prototype,” we think of a complex device that may still have some rough edges and is the first and only of its kind. Prototypes are generally associated with industrial machines and mechanisms. However, prototyping is used across industries. This also includes cosmetics.

So let's look at some practical insights into cosmetic prototypes.

The cosmetics industry

The cosmetics industry is a rapidly developing industry. 300,000 new cosmetic products are produced every year. Just a few years ago, the cosmetic industry consisted mainly of a few large corporations that had extensive resources for producing synthetic and rare ingredients. But then a trend towards environmentally friendly natural cosmetics arose. With the emergence of the “natural” trend, the industry changed. Most organic ingredients can be extracted without complex equipment, and many small local businesses have emerged offering natural, homemade products.

Many people are allergic to some ingredients. For this reason, the United States Department of Agriculture (USDA) National Organic Program has developed a policy that provides guidelines to regulate the composition and use of synthetic ingredients in various cosmetic products. Manufacturers must consider both the effects of the product they produce and the ingredients used. According to the NSDA, all cosmetics are divided into four groups:

  • 100% organic. This means that ALL ingredients must be natural. This type of product is the most difficult to produce, as natural ingredients spoil much faster, but it is currently the most expensive and most successful cosmetic product.
  • Organic. 95% of the product is natural. These are generally products that contain some non-organic elements, the natural analogue of which is not commercially available. It is still a very useful and effective composition.
  • Made with over 70% organic ingredients. Or three types of ingredients. These are mid-range products. Products that are very good and have a good price, but don't come close enough to the market leaders.
  • Made with less than 70% organic ingredients. The cheapest and mainly synthetic products. They are generally manufactured by companies that have a lot of conventional and complex equipment and maintain their price based on brands and sales volumes.

The importance of cosmetic prototyping

Of course, every cosmetic product is potentially very harmful. Most of them come into direct contact with our skin, some with our eyes and hair. For this reason, strict standards apply to the certification of these products. To obtain certification, a series of tests must be completed.

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First, chemical tests determine whether the product reacts unexpectedly to certain common elements (such as water or heat). Even today, accidents still happen when a cream or shampoo becomes unexpectedly toxic when it comes into contact with another cosmetic mixture. Each product must react to human skin and other elements so as not to endanger people. Allergic reactions are also important with these products. If the mixture contains active elements that can cause allergic reactions, they must be replaced or information about them must be recorded in writing. At this stage, a first prototype is made and the final composition is determined.

Then, laboratory tests determine the actual performance of the product. When a new solution is created, it is typically compared to an existing reference product. This helps determine performance and describes the requirements it must meet. At this stage, a pre-production prototype is required.

Finally, there is a real testing phase in which the product is distributed to several people who use it on a daily basis and evaluate its effectiveness. Previously, tests at this stage were carried out on animals, but this practice was frowned upon at the beginning of the 20th century and is now completely illegal in many countries.

Production of cosmetic prototypes

The production of cosmetic prototypes is mainly a chemical process and involves several steps.

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Once the product idea has been formed, an initial prototype is produced by the developer himself. The product may not contain all the necessary ingredients (for example, those that preserve it) and may not have the required texture and appearance, but it will perform exactly as the final product should.

Next, a pre-production prototype must be made, which is normally not possible without special laboratory conditions. Most modern laboratories have a special mixer that contains ingredients and air is sucked out. This prevents the formation of unwanted chemical reactions and air bubbles in the product during mixing. Often the mixture is heated to the boiling point. Toothpastes and shampoos, for example, are practically cooked at a temperature of 70°C.

After mixing the ingredients, the new product must remain in the vacuum chamber for some time. In general, the process takes 2 to 6 hours and has the disadvantage of producing a lot of product. Less than the vacuum chamber minimum cannot be done.

The final testing phase is characterized by the fact that a significant quantity of cosmetic products has to be produced. When the mixing part is practically the same, the packaging manufacturing process is included in the production chain. At this stage, if the tests go well, the packaging design is usually created. In some cases, the issued prototypes are already included in the final packaging. This means that the molds and other tools have already been created and the first quantity therefore includes all initial investments for the entire product. If the test fails, the manufacturer will incur huge losses.

University Degree

Cosmetic prototyping is a rapidly evolving industry and hundreds of thousands of cosmetic products are manufactured each year. However, due to potential risks to human health, this industry is subject to strict regulations. The certification process in the cosmetic industry is very similar to the medical certification process and is therefore quite rigorous. The certification process consists of three phases: initial testing, laboratory testing and real-world testing. Starting with initial testing, each phase requires a prototype and the final phase essentially requires the creation of the product. Rapid prototyping is therefore extremely important in this industry.

After reading this useful information, you will have a comprehensive understanding of the application of rapid prototyping. Wayken has already designed perfume bottles in this area. If you want to know more, don't hesitate to contact us.

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