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Saimoun
Custom packaging for your product - how?
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on: April 19, , 06:59:32 am »
Hi
I already asked a few months ago and already got some (very helpful) answers but I have now a more concrete situation
I have a product which has a rectangular shape 126x75x39mm, but also has a large round knob of 32x14 (see picture).
Is cardboard a good solution for packaging it, and will it be "easy" for a manufacturer to construct a cardboard box that will "fit" the device, including the knob (and not just a simple rectangular shape)?
I.e. something like that:
Or should I go for something else, like a simple cardboard with a foam insert f.x.?
Thank you
lutkeveld
Re: Custom packaging for your product - how?
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Reply #1 on: April 19, , 07:19:21 am »
Blister inserts are also a cost effective solution and can be made from ESD safe material
SeanB
Re: Custom packaging for your product - how?
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Reply #2 on: April 19, , 09:12:45 am »
Custom cardboard boxes are cheap enough, you will pay however for the design of the cutting dies, and also they tend to have a minimum number of units you have to order. Can you not see if a manufacturer of cardboard boxes has a ready made version that will suit you, and then simply make a cheaper cut board to have the knob supported, which is a lot cheaper to do, and your box at least will be off the shelf size wise. Pretty much all corrugated carton manufacturers will do so, and try your local suppliers first, then look at neighbouring countries, Poland will probably be cheaper than Denmark because of lower wages, so try there as well, and shipping will be easier for this, as cardboard shipping is quite expensive, as it is done using volumetric mass.
Otherwise a regular box and a die cut foam insert, either in polystyrene, or other foams if you need more flex, or a custom cut urethane foam for fragile parts, but those are both more expensive and less environmentally friendly as they are typically harder to recycle, unlike cardboard.
AlexanderB
Re: Custom packaging for your product - how?
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Reply #3 on: April 19, , 12:25:25 pm »
From the slightly more hack perspective, 3d print a mold and use shredded cardboard flakes soaked in water to press inserts, egg carton style?. Probably not the best way to go about it, but it's an option, and probably very eco friendly.
For small batches you could also consider laser cutting the cardboard inserts, no need for custom tooling and minimum batches that way.
beanflying
Re: Custom packaging for your product - how?
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Reply #4 on: April 19, , 01:54:58 pm »
Raw cardboard outers are a good fairly tough way to pack and if you use a good inner then shipping can be done in a plastic bag to save some money that end. Also using a well designed inner might let you use a 'standard' outer box which will be a lot cheaper in small quantities for you.
For your inners cardboard is still an option and in small runs Laser cutting will compare well against having a die made.
Blow molded or Vacuum formed inner can be done but they provide little to zero additional protection to your device so you are going to be relying on your outer.
Laser or hot wire cut and glued EVA or EPP foams are a good solution for lower quantities. I did a small custom insert job recently for myself below just as an idea of the cut result. Plenty of crush and shake protection with this option and also within reason a low damage or marking solution for your product.
Also found a few pics of a Fusion 360 model I was playing with and produced in some cereal box cardboard Sheetmetal part of it if anyone is interested
« Last Edit: April 19, , 02:01:34 pm by beanflying »
Coffee, Food, R/C and electronics nerd in no particular order. Also CNC wannabe, 3D printer and Laser Cutter Junkie and just don't mention my TEA addiction....
Saimoun
Re: Custom packaging for your product - how?
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Reply #5 on: April 20, , 07:49:54 am »
Hi all
Thank you for your replies! It helps a lot
I think I really like the all-cardboard option then, both for the prototypes but also for when we go to production. Cheap and environmentally friendly seems perfect!
And very good point about using an outer box that is already the right size, then yes only the inside piece needs to be custom made
phil from seattle
Re: Custom packaging for your product - how?
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Reply #6 on: April 20, , 09:54:56 pm »
Hi all
Thank you for your replies! It helps a lot
I think I really like the all-cardboard option then, both for the prototypes but also for when we go to production. Cheap and environmentally friendly seems perfect!
And very good point about using an outer box that is already the right size, then yes only the inside piece needs to be custom made
One thing to be aware of, box measurements are often imprecise. I have bought three different 4x6x1.5 boxes for shipping and they all have slightly different actual dimensions - a bit more than 1/4"/6mm difference.
Saimoun
Re: Custom packaging for your product - how?
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Reply #7 on: April 21, , 07:24:10 am »
Ok nice to know
I actually got one of the manufacturers to design the inner for me, they will know their own tolerances so that should be fine
Do any of you use custom cardboard boxes? I have some products that I am making it would be awesome if I could get some boxes made up with my logo on on them, and the size to fit each product. However, this is totally new to me, so trying to dig up info of min order amount, apprx. cost, any tooling costs, who to try calling (printing shop?) etc.
Thanks!!!
I just switched to Corrugated Cardboard Boxes | Shipping Supplies | Shipping Boxes | Packaging Supplies
They have better pricing than i had with Imperial Packaging.
I looked into custom boxes at Imperial and set-up was expensive unless you are doing a big volume.
I have found it's much more cost effective to get a standard size box close to the size i need and use peanuts to make up the volume.
Also, I have switched to folding mailer boxes over standard boxes. They use no tape and seem stronger IMO.
caspian
I inadvertently used custom boxes. At the time I was remanufacturing large numbers of locomotive braking and reversing switch contacts. Wrapping for shipment individually was time consuming and the the customer had to unwrap them. St. Louis Paper and Box worked up a package with cardboard inserts punched to hold the parts. The inserts came flat with the openings punched and scored to fold in the right places for support. The result was a very professional package with a laser printed label on the identifying the part so the customer could warehouse them in their boxes and inventory them at a glance. Unfortunately, that business came to an end and I wound up with a lot of left over boxes. I suppose the box designer optimized the container for my parts, but they were 14 1/4 X 7 7/8 X 5 1/8. When I tried to sell them, I found that I had paid 4 or 5 times the price for a standard box about that size and people were going to give me than less than the standard price. I just kept them and use them whenever I need a box.
The setup served well for a number of years, so I can't really complain.
St. Louis Paper & Box
Garfield Ave.
St. Louis, MO
314-531-
St. Louis Paper & Box - Packaging Materials - Boxes - Tapes - Cushioning & Dunnage - Plastic Films - Bags - Strap
Ask for Luanne. Don't be put off by her hillbilly accent. She is about as country as they come with no apparent higher education, but she gets right on a job and gets it done.
Bill
Custom boxes are expensive. We did a cost reduction last year and found it was cheaper to use more Insta-Pak than it was to stock 4 additional sizes of boxes.
You'll have a tooling charge for each size of box. A couple of hundred to over $1K depending on box size, complexity, and layers of corrigation. The the silk screen charge. Then you have the set-up charge for making your boxes. This can be a couple of hundred for a small order to nothing for a large order.
I've got a buddy that sells a product. He buys plain boxes, uses Insta-Pak, and then stencils his logo on the side. He has his stencils made from stainless on a water-jet. He ships anywhere from 1 to 10 boxes a day.
JR
I use custom boxes to fit a product much like describes. York container in York PA makes them for us. There are thousands of box makers in the US, there should be one within driving distance for you, there are about 5 near me.
I recently bought some low production box making machines to make in process boxes for shipping parts to plating and heat treat etc because the setup charge on just a few is too high to get them made. I have an air/manual machine I don't need and will be selling if you are interested - about $, makes the cuts and scores so you can fold them up and glue them together.
One of my customers in the print trade buys the slightly more expensive but darn sight nicer white outer boxes. Same as normal corrugated but the outer skin is a white not brown card. He then hand stamps them with a 8" stamp hand cut out of soft neoprene. Makes a surprisingly large stand out difference to plain boxes and looks darn professional. His logo lends its self to being stamped at a sorta 30 degree angle though so getting it square is not even a issue. They only probably go through a few hundred boxes a month though!
ordinary boxes are called RSC [regular slotted cartons] and there are not tooling charges, the more you buy the cheaper, a small shop would do 100 for you for a decent price. Printing plates are expensive, but set type is free. So if you just need a PN or your co name in plain type, no charge. Getting into custom die cuts and plates gets pricey fast!
I find ULINE is competitive for often up to 200 pieces or so and they use a real good quality board.
If you want fancy graphics, print them separately and tip [glue] them on.
Wow, thanks guys! I am in SE part of the state, so will likely have to have them shipped to me. Thanks for the leads!
One of the things is its pretty low volume, about 100 of each box size should be good for me for awhile. The parts are firearm barrels I make-so it takes a long narrow box. Something along the lines of a jewelry box, or one of those boxes that has a lid that fold down and tucks in would be downright awesome!
Mud, thanks for the offer of the machine, but I think right now as long as someone could do them at a reasonable cost, we'll go that route.
I'll have to try to get in touch with some people and see what I can come up with. Its encouraging to hear this is possible!
Thanks again!
I make a laser cut Aluminum or Titanium frame coping/fret/jewelers saw that takes a lot of space in a box. I tried all of the various flavors, and settled on a 12" pizza box. They are super cheap (about .50cents ea), made from recycled materials, and are amazingly sturdy when paper taped tightly. I ship them literally around the world by USPS priority mail, and have had only one that failed (they drove over it with the truck).
To secure the frame in the box, I gang saw egg flats into individual cones and place one on the handle. The entire package weighs 12oz, and ships anywhere in the states for about $6.00.
The cost of packaging can eat you alive.
Lee (the saw guy)
knewconcepts dot com