Graduate Thesis Or Dissertation
 

Automated Design of Foam Packaging Shapes

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/pz50h4198

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  • Creating effective packaging is about finding a balance between product protection during shipping and time consumption in the design process. Given time and cost constraints, it is hard to produce sufficiently protective padding while having it not be thicker than it needs to be. This thesis describes a method to automatically generate foam packaging shapes based on of a product’s known shape and shock limits. Starting with a 3D model of the product, an initial rectangular prismatic foam shape is created through directional overhang removal, bounding body creation, and Boolean subtraction. Directional overhang removal is done using a process called sequential slicing and extrusion. Next, using foam stress-strain curves, one-dimensional dynamic simulations are run on each box side to determine the appropriate foam thickness and cross-sectional area. Three examples of directional overhang removal are provided and a table is presented with different foam thicknesses for products of different shock limits, weights, and dimensions. The research efforts are being used in a CAD plugin to simplify packaging decisions and speed up design.
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  • LAM Research
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