Structural Engineering for Custom Packaging
A structure has to satisfy three masters at once - the product it protects, the brand it presents and the carton it ships in.
At a glance
- Declared internal clearances per SKU
- Insert geometry for single or multi-component sets
- Drop and stack testing on the packed unit
- Reinforced bases for heavy contents
Overview
A structure has to satisfy three masters at once - the product it protects, the brand it presents and the carton it ships in. Our engineers work backwards from those constraints to a dieline that can be manufactured repeatably on the floor.
Buyers in North America, Europe, the Middle East, Australia, New Zealand and Brazil rely on this because it removes ambiguity at the quotation stage.
Fit and Protection
Internal clearances are set from measured product dimensions plus a declared tolerance, then validated with a white mock-up and a simple drop test. Inserts are designed to locate the product rather than merely fill space, which is what prevents scuffing in transit.
- Declared internal clearances per SKU
- Insert geometry for single or multi-component sets
- Drop and stack testing on the packed unit
- Reinforced bases for heavy contents
All of this is confirmed in writing before a deposit is requested.
Manufacturability
Crease direction, grain, glue-flap width, wrap overlap and closure tolerance are all specified on the dieline before it reaches the die-maker. That detail is why a hand-assembled rigid box closes squarely across thousands of units rather than only on the sample.
- Grain direction and crease allowance
- Wrap overlap and corner specification
- Magnet or ribbon closure tolerances
- Assembly jig definition
If your brief differs, tell us the constraint and we will propose the closest workable build.
Freight Geometry
Where a programme ships direct to consumer, we can engineer a fold-flat or collapsible variant that cuts volumetric weight substantially. Carton counts are then calculated from the assembled or flat dimensions so the container plan is accurate at quotation.
- Flat-pack and collapsible structure options
- Carton count and pallet plan
- Cube optimisation for air and sea freight
- Retail-ready versus ecommerce trade-offs
If your brief differs, tell us the constraint and we will propose the closest workable build.
Frequently Asked Questions
- Do you test the structure?
- Yes. White mock-ups are fit-tested, and packed units can be drop- and stack-tested before production.
- Can a rigid box ship flat?
- Certain collapsible and magnetic formats can. We will show the cube saving and any trade-off in rigidity.
- What tolerances do you work to?
- Tolerances are declared on the dieline and agreed in writing for the specific construction.
Ready to specify your packaging?
Send your artwork, target size and quantity. Our engineering team replies with a structural suggestion, an FOB price and a sampling plan within one working day.
Related Resources
Materials library
Canfei Packing buyer resource
Printing capabilities
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Finishing techniques
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Sampling workflow
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OEM & ODM
Canfei Packing buyer resource
