Creative Commons License

Creative Commons Attribution 4.0 International License
This work is licensed under a Creative Commons Attribution 4.0 International License.



This research exhibits the cushion design process for protecting a product during the distribution environment and examines the effect of the final design by ISTA 1A drop tests. Currently, few research on the principles of cushion design in protective packaging has been undertaken. Rare research on cushion configuration and its performance. The study started with proposed several cushions distribute layouts - face pad, edge pad, and corner pad, along one orientation. Samples were tested, analyzed, and compared by static compress and dynamic drop tests. After manufacturing and engineering consideration were involved, two improved cushion configuration designs were applied to three dimensions, followed by analysis, compared by dynamic drop tests and improvement. The final cushion design, developed from materials, fabrication, and mechanicals, stood out, and its performance was measured and verified the validation. The study used a cutting table, environmental conditioning chambers, a compression testing system, a drop tester and SaverTM (a data recorder). The statistical analysis of the drop tests confirms that the final cushion design is corner cap structure with bearing areas and lateral components for cushion and connecting, respectively. This study’s conclusion shows some principles of foam cushion design, which should be valuable to packaging engineers in the design and evaluate cushion structure while improving their cushion performance.