Laser Plastic Welding for Bio-Based Sports Drink Bottles

Laser Plastic Welding for Bio-Based Sports Drink Bottles: A Reliable, Automated Manufacturing Solution for Fassibottle and Evosys

Innovative material and manufacturing concepts are becoming increasingly important. A recent example of this is the bio-based sports drink bottle from Fassibottle, which will be welded in our Evosys contract manufacturing facility in the future.

The vacuum-free bottle is made from renewable sugarcane. Through targeted design adjustments, the bottle is prevented from collapsing while drinking, ensuring a consistent and unobstructed flow of liquid. At the same time, the bottle retains its shape during use, thereby meeting the requirements of many top athletes and finding particular application in cycling.

In the original product design, the valve concept in particular posed a challenge. It consisted of several individual components such as the valve, seal, and nut, which required labor-intensive manual assembly. In addition to the increased manufacturing effort, this also resulted in a functional risk: the valve could be opened by the end user, which could compromise both the seal and product safety.

To optimize the design and manufacturing process, laser plastic welding was implemented as the joining technology in consultation with Evosys and Fassibottle. This process enabled the creation of a permanent, unbreakable bond between the valve and the bottle body. The particle-free joining process ensures that no contaminants are introduced into the drinking system—a decisive advantage, particularly in the food and consumer goods sectors. Furthermore, laser plastic welding enables short cycle times and high process speeds, significantly increasing cost-effectiveness in series production.

Another advantage lies in end-to-end process integration: From the production of the bottle body and the punching of the bottle base to the insertion of the valve, subsequent welding, and final assembly, the entire production process can be efficiently and automatically managed. This reduces interfaces, minimizes sources of error, and ensures consistently high product quality.

Do you have any questions? We’d be happy to advise you on a specific application.

Our contact information:

Phone: +49 9131 40180-0

Email: info@evosys-services.com