Digital Twin Model of Paper–Aluminum Laminates for Sustainable Packaging

The proposed integrated experimental and simulation study focuses on the mechanical behavior and failure analysis of coupled paper-aluminum (paper-Al) laminates for sustainable packaging. The research employs an innovative experimental approach combining uniaxial loading with in situ visualization of sample deformation. The acquired experimental data are utilized to validate a simulation model, ensuring its accuracy and reliability. Parametric studies conducted through the finite element model further enhance our understanding of the mechanical behavior of the coupled laminates. Specifically, the study investigates microscopic mechanisms influencing the overall response of laminates in both the machine direction (MD) and the cross-machine direction (CD), presenting a comparative analysis with traditional aluminum-polyethylene (Al-PE) laminates, which is a prevalent choice in the packaging industry. The findings contribute to a better comprehension of key factors affecting the mechanical behavior of paper-Al laminates, enabling the design of more effective and sustainable solutions for the packaging industry. Results indicate the advantage of increasing the laminate thickness in the MD, demonstrating an enhanced strength. Conversely, the sensitivity of the thickness variation in the CD is found to be less pronounced. Additionally, our investigation highlights the substantial potential of paper-based materials as environmentally friendly alternatives, particularly in contrast to Al-PE laminates. Furthermore, integrating an innovative digital twin model, which combines experimental data and simulation, significantly advances our understanding and application of laminated in the context of paper packaging design.