When you're developing a new product, its packaging is probably the last thing on your mind.
There’s already plenty to think about: refining the product, working through prototypes and getting ready for that first production run.
Packaging can easily get shunted to the bottom of the list - a conversation to happen when everything else is finished.
But with our twenty-plus years of experience in industrial packaging, we’d advise against it. “The best time for us to start on a project is as soon as a prototype is available, or even the CAD model,” says SmartShield's Design Manager, Ashley Botterill.
Getting your packaging partner involved early means you can understand your options, get a realistic idea of costs, and catch important requirements before they become a problem later.
If you have a CAD model or prototype available, that's often enough for a packaging design team to start exploring concepts.
“If customers can share CAD models of their prototypes, we can come up with packaging concepts to give them an idea of cost and what the options are ahead of their item being manufactured,” explains Ashley.
Building in this extra time is particularly useful if the first solution isn't what you expected.
It's not unusual for a manufacturer to have an idea of the packaging they'd like, only to find the cost is higher than anticipated.
For example, you might initially request a high-quality plastic case with a highly customized foam insert. Once you see the cost, there may be opportunities to rethink the design and ask questions such as:
A rigid board carton isn't the same as a standard corrugated shipping box. It's made from a more substantial solid board – think of the construction of a high-quality puzzle box – and can be worth exploring when a heavy-duty plastic case isn't necessary.
Getting your packaging partner involved early gives you time to explore those alternatives and find the right balance between protection, usability and budget.
And if you do need to go back to the drawing board, you can do it without a shipping deadline breathing down your neck.
Another advantage of involving a packaging specialist early is that we know what questions to ask. One of the big ones is surprisingly simple:
What actually needs to go in the package?
It's easy to focus on the main product and forget about everything that needs to travel with it. This can be particularly relevant with medical equipment. A manufacturer might initially provide details for the main device, only to realise later that the package also needs to accommodate power cords, different-sized applicators or other accessories and consumables.
Discovering those additional items after the packaging has already been designed could mean having to rethink or modify the original solution.
A good packaging partner will discuss the wider requirements from the outset, including:
Understanding those details earlier means they can be built into the proposed solution from the start, rather than becoming a change, and potentially an additional cost, later.
Starting early doesn't mean the packaging design has to be set in stone.
Once the first production units are available, your packaging partner will be able to review them against the solution proposed from the prototype or CAD model and make sure it's still suitable.
If the production product has changed, or there are additional requirements that weren't apparent at the prototype stage, the packaging can be adjusted accordingly.
This creates a much more natural process:
CAD model or prototype → packaging concept → production unit → review and refinement → testing and certification where required
Rather than waiting until the product is finished and trying to complete every stage of the packaging process at once.
Starting the packaging process early doesn’t mean everything needs to be tested and finalized at the prototype stage.
We wouldn’t normally expect customers to carry out shock and vibration testing on prototype equipment if that testing can’t be used for certification.
Instead, we use the prototype or CAD model to get a head start, developing the packaging concept, exploring different options and making sure we’re heading in the right direction.
Then, once the production units are ready, we can review the proposed packaging, make any necessary changes then move on to formal testing and certification where required.
You don't need to wait until your product is sitting on the production floor ready to ship before talking to us about its packaging.
Getting SmartShield involved at the prototype or CAD stage gives everyone more time to understand the requirements, explore different options, identify potential costs and make changes without creating a last-minute rush.
And as your product develops, your packaging can develop alongside it.
Got a prototype or CAD model ready? Talk to the SmartShield team about your custom packaging requirements.