Hugger Module – From Concept to Operational Integration
The Hugger Module is positioned directly after the last knife fold in the pharmaceutical folding process, where inserts and outserts receive adhesive to complete the final fold. At this stage, skewing is common, which can lead to alignment issues during pressing and inspection.
This module actively corrects skew before the inserts reach the pressing unit, ensuring that the adhesive is sealed properly and alignment is preserved before the glue sets. By stabilizing orientation at this critical point, the Hugger improves downstream accuracy and reduces rejection rates during inspection.
This page documents the full development process — from concept sketches and CAD design to 3D-printed prototyping and final implementation — illustrating how this system solved a key production issue with a compact, mechanical-first solution.
This gallery features a working 3D-printed prototype developed to validate the Hugger Module concept before formal CAD design began. Connected to a Raspberry Pi and microcontroller, this early version was used to simulate basic functionality and confirm that skew correction was feasible using a compact, motor-driven mechanism. These tests provided critical validation that informed the full production-ready design.
Gallery 1: Early Development and Conceptual Prototyping
Gallery 2: From Drawings to Final Designs
This gallery highlights the finalized design phase of the Hugger Module, featuring full CAD renderings and dimensioned technical drawings. Shown here are both the original short Hugger and the later extended version, each refined to meet changing production requirements. These images demonstrate critical updates in geometry, size, and form to improve alignment control and system compatibility.
Gallery 3: The Hugger Module in Action
This gallery shows the transition from the original short Hugger to the final long version, along with its integration into two system configurations. Images include the long Hugger installed between the 9th fold and the pressing unit, and a later version paired with the reject module. These examples highlight how the design was adapted to fit evolving production needs.
Live Testing of Near-Final Hugger Prototype (Hybrid 3D-Printed Build)
Proof of Concept: 3D-Printed Skew Correction Prototype
Installed Long Hugger in Final Line Configuration
This video demonstrates the early 3D-printed prototype used to validate the Hugger Module’s ability to correct skew before full system development.
This video shows the near-final Hugger prototype in live testing between a feeder and curing module. Most of the frame and pulleys were 3D printed, while key components like T-slot rails, belts, motors, and bearings were integrated to ensure reliable operation.
A look at the Long Hugger module installed between the last knife fold and the pressing unit in the live production layout.