Structural Design Tips for Packaging

Structural Design Tips for Packaging

Win on protection, cost, speed, and sustainability—without sacrificing brand. Below are proven structural tips we use at Influence Packaging to deliver right-sized, first-time-right solutions.

Right-Sizing Stronger with Less Faster Assembly Mono-Material Options

1) Start with Internal Fit (L × W × H)

Design from the inside out. Measure internal dimensions at the opening and specify L × W × H. Add clearance for product, inserts, and handling tolerances (corrugated typically ±1/8″ / ±3 mm).

2) Choose the Right Material & Flute

MaterialApprox. Caliper*Typical Uses
Folding Carton (SBS/CRB)0.014–0.024″Retail cartons, sleeves, small device packs
Corrugated E-flute~1/16″ (1.5–2 mm)Mailer cartons, print-heavy e-com
Corrugated B-flute~1/8″ (3 mm)RSC shippers, inserts, trays
Corrugated C-flute~5/32″ (4 mm)Heavier products, stack strength
Double-Wall (BC)~1/4″ (6–7 mm)Large/heavy items, pallet stacking

*Calipers vary by mill/spec; confirm with your converter. Select ECT/edge-crush for stacking needs.

3) Engineer Closures for Speed

  • RSC (Regular Slotted Carton): cost-effective shipper; tape close.
  • FOL (Full Overlap): stronger top/bottom for heavy goods.
  • Mailer w/ locking tabs: quick assembly; good for DTC unboxing.
  • Auto-bottom / Crash-lock: fastest assembly on pack lines.

4) Score, Crease, and Allowances

  • Mind the **score-to-cut** distances and **min panel widths** recommended by your plant—avoids tear-outs and crush.
  • For folded wraps, allow for **material take-up** (board thickness) at tight turns.
  • Call out **glue areas/no-print** zones on dielines to prevent adhesion issues.

5) Inserts that Do More with Less

  • Switch foam to **corrugated/PB engineered inserts** or molded fiber where practical.
  • Design for **multi-drop protection** (edges first) and easy pack sequence.
  • Target **mono-material** (paper-only) systems to improve recyclability.

6) Cost Through Design

  • Right-size to cut **DIM weight** and freight; 1–2″ reduction can be material.
  • Optimize **sheet utilization** (common footprints, shared tooling).
  • Standardize closures and board grades across SKUs for scale savings.

7) Test Early, Iterate Fast

  • Proto & test: quick CAD cuts → pack trials → transit testing (e.g., ISTA 3A as appropriate).
  • Track damage modes and revise insert contact points first.
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