5 Design Tips to Protect Parts During Shipping

Shipping can be rough on parts. Vibration, impact, and stacking often cause damage. By incorporating simple design features, you can dramatically reduce breakage and returns.

First, avoid thin, unsupported sections. Long, slender features tend to flex or snap. Add ribs, gussets, or increase wall thickness where possible. This strengthens the part without adding much weight.

Second, round all corners and edges. Sharp corners are stress raisers and chip easily. A small radius of 0.5-1mm can prevent cracks from spreading.

Third, design for nesting. Parts that stack neatly or interlock reduce movement inside the box. Consider adding alignment features or symmetrical shapes.

Finally, involve packaging engineers early. A simple change like adding a boss for a foam insert can save money and damage. Prototype and drop test your design to verify it survives the journey.

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