Electronics are damaged by three things in transit: impact, vibration and static. A good pack handles all three, in that order of cost, and it does so in layers rather than by adding thickness everywhere.
Build the pack in layers
- Against the device: a bag or wrap. Anti static for exposed boards and components, a plain poly bag or a soft sleeve for a finished enclosure to prevent scuffs.
- Retention: a fitment that holds the device in position. Die cut corrugated, moulded pulp, foam end caps, or a suspension film pack that holds the device between two membranes.
- Cushioning: the gap between the retained device and the box wall, filled with foam, pulp, air or paper depending on weight and fragility.
- Outer box: corrugated sized to all of the above, with enough board to take a drop onto a corner.
- Accessories: cables, chargers and manuals in their own compartment so they cannot press into the device.
Retention or cushioning
| Approach | How it works | Suits |
|---|---|---|
| Retention pack | The device is held against a film or fitment and does not move | Flat, rigid devices: tablets, boards, drives |
| Suspension pack | The device floats between two membranes, away from every wall | Fragile items where no face should take a direct hit |
| Moulded fitment | Pulp or foam cut to the device profile | Volume programmes with a fixed device shape |
| Void fill | Loose material packed around the device | Low volume, mixed SKUs, least protective per unit of space |
Static, moisture and the small stuff
Static damage is invisible until the customer powers the device on, which makes it the most expensive failure in this category. Use anti static bags for anything with exposed contacts or bare boards. For moisture, a desiccant sachet inside a sealed bag is cheap insurance on long sea transits, and the cost saver lane is a sea lane, so plan for it if that is how your goods travel. Small accessories are worth compartmentalising: a loose charger sliding around inside a box will mark a screen.
Batteries: check, do not assume
Lithium ion and lithium metal cells are regulated in transport, whether they ship installed in a device, packed with it, or on their own. The requirements cover marking, packaging and documentation, and they differ by mode, by carrier and by configuration. Confirm the current rules with your carrier for your specific product and route before you commit to a pack design. We build to the spec you confirm, and we do not certify that a pack meets a transport regulation.
Specifying the box
Give us the device dimensions and weight, the retention method you want, the accessory list, and whether the pack is retail facing or a plain shipper. C flute at about 3/16 inch caliper covers most single device shippers, with double wall for heavier units or long transits. E flute is the usual choice for a printed retail carton that sits inside an outer shipper.
The minimum is 100 boxes, pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote, and turnaround is quoted per product in three lanes: rush, which is expedited production plus air freight, standard on air, and cost saver on sea, from about 7 business days in production plus 2 to 5 days for delivery. The die, the plates, design support, US shipping and a digital proof are included, so a fitment cut to your device carries no tooling charge.
For a device specific worked example, see laptop box dimensions. To order the outer, see custom shipping boxes, or send your device measurements with a quote request.
