Product Packaging

Objective: Develop foam packaging inserts to protect an expensive product from drop damage while minimizing per-unit cost for an initial 30-unit run, with scope for future replenishment orders.

Mechanical Design

Process:    

  • Modeled multiple insert geometries in SolidWorks and iterated each design to reduce material use while preserving cushioning performance.

Finished Product

Results, Testing & Validation

  • Reduced unit cost from $66.75 to $6.35 through foam volume reduction and CNC setup cost elimination, an initial amount saved of $1,812; all future order with a 90% cost reduction.
  • Conducted multiple drop tests on the foam packaging inserts and achieved zero damage in every trial.