Internship Project

Along with learning the ropes of packaging design, making standard CADs and cutting samples, and getting to visit other packaging manufacturing plants in the area, I got the opportunity to really use my creative problem-solving skills on this unique project

Project Brief

Damaged box with a damaged product in the box. The hollow cylindrical product gets shipped around a lot for events and gets reused in the same box. UPS and Amazon workers weren't handling it gently, and the inner pieces did nothing to protect it.

Goal

Ideation

Create parts that protect the box from being damaged by the product, protect the product from external forces, can last a long time, is cheap to manufacture, multi-purposeful, and is innovative and unique

I liked the structure of this, but I decided it was too many pieces for someone to assemble, time consuming, unnecessary cost + material

Low cost

Less pieces

Easier to assemble

Easy to Manufacture

Experiementation

Things I experimented with:

Flute Direction

Different flute variations

Hole circumference size

Hole Depth

Size of the arial-structure

Using 2 the same piece to make the structure

Using 2 different pieces to make the structure

Drop Testing

Successful! No damage to product

First Design Set Sent to Customer

Part B

Part A

Box

Made these extra cuts to keep a big cord form interfering with the design flush on the top of the cylinder.

Problem:

Takes away from the strength

Design Features

Corners cover the switch and protect it from the box

Space for additional materials that come with the product

Cut outs help keep the part's surface flush

51 Double Wall BC corrugate adds to strength

Horizonal Flute direction adds extra strength the structure

Points keep the product from getting damaged on the sides

Raised arial-structure keeps the product from damage from top and bottom

Final Product

Part B

Part A

Box

Assembly Instructions

Customer Review from the Sales Representative

"For the very first time in Gold Medal history they loved it as is and had no further delaying and timely requests.😯I cannot thank you enough for the fantastic design work on that set."

"Since they have been experiencing damage to their products with the current design by irresponsible employees at both FedEx and UPS, they have pushed these forward and want to order them next."

"Once again, great job providing a solution to a customer who had a problem. It's because of solutions like these that make it easy for me to ask for more business and expand their spend with us."