How to do final packaging for production? - Page 1
Forum section: electronics / general

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 23, 2021, 04:56:01 pm
content: Hi!I have a product which is closed to being finished, I found a PCB (+assembly) and a case manufacturer in China. I am making a 1000 units which will need shipping to different locations around europe (EU only).What about packaging, how do you guys package your electronics "for production"? I am thinking from like the design of the cardboard box to shipping to final customer.I tried to find card board manufacturers (on alibaba f.x.) but could not really find one that seems to handle electronics packaging (most of them were like for gift or jewelry) - any advice on what words to look for?Thanks!Simon

author: jmelson
author_rank: Super Contributor
timestamp: February 24, 2021, 12:50:50 am
content: Look up ULINE in the US, for an idea of what sorts of boxes are commonly made for commercial shippers. We use their "catalog mailers" boxes.Jon

author: Kean
author_rank: Unknown
timestamp: February 24, 2021, 06:24:55 am
content: If you haven't done this before, then I'd suggest first working with someone more local than China. If your product is of significant value, then you want it properly packaged. Or ask your assembly house for suggestions, as having them pack and ship it in the final packaging may help. Either way, you'll probably want some extra packaging for handling customer returns and so on.I'd suggest doing a local Google search for something like "custom cardboard or foam inserts for boxes". Contact one or more companies to see what they can do, and get an idea of pricing. They'll likely need a sample product or at least accurate size and weight info, and some guidance on how you want it protected/presented/labelled. You can then decide if custom cut cardboard or foam and printed die-cut boxes is within your budget, or whether you should just stick to simpler packaging like bubble bags and off the shelf cardboard cartons.I'd also expect many of the companies on AliExpress that offer custom boxes for jewellery should also be able to help. It is just that jewellery is a small high value item that people like to present well. There are lots of people crafting custom jewellery on places like Etsy that want low cost but presentable boxes. The factories will likely pump out packaging for all kinds of things.

author: Berni
author_rank: Super Contributor
timestamp: February 24, 2021, 07:29:02 am
content: Look for some local companies that can make boxes for you. Printing houses tend to offer this service since a lot of product boxes also have printing on them. Just instead of printing on regular magazine paper they print it on cardboard. And if they do so they will likely also have the required equipment to turn a flat cardboard sheet into a box. You might want them to print your instruction manual booklet anyway if its a large volume product.If you also want foam inserts, they probably won't have the capability for it, but ask anyway, maybe they do, and if they don't they probably know someone that does.

author: 48X24X48X
author_rank: Frequent Contributor
timestamp: February 24, 2021, 08:40:26 am
content: It really depends on your budget. If your product is already so close to completion I believe you have never really thought of it or thinking that it is a simple task. In one of a product I made for a client, the client had the box designed by an ID and made by a factory in Shenzhen that made boxes for Apple and Google (most of those section of the factory are covered and not allowed to go in). We went there a few times and it does take long months of iteration and prototypes to reach the end final product. But, there are also on the other end of the spectrum where the cost is not that high but you still get a decent packaging (probably using an existing die cut and some printing of logo and what not on it). Try searching on Alibaba as a start and if you are not afraid to deal with Taobao sellers, that will open up more choices. Use a fulfillment house probably in Hong Kong, and they can store, manage, pack and ship for you as orders come in directly to your customers in EU.

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 24, 2021, 09:38:07 am
content: Thank you all that is super helpfulYes the product is "close" to completion, but there is still a long way to go, we hope to sell the first 1000 within the year, ideally by the summer.So far my experience with the Chinese market is really great, I spoke to many PCBA house and case manufacturers and it went really well.So I am sure it will be the same with the card board boxes. Difference is for the electronics and the case I had the design ready, while for the packaging I have no ideaI will try the ones I found on alibaba then, hoping they can make more than jewelry boxesAnd yes I imagine any factory that can make the box would be able to print the documentation as well.So in conclusion my biggest issue right now is the design of the box... I think I will go for 100% cardboard - but folded and cut so the device fits nicely and is well protected - as it would be a good bargain between low cost and a professional look, is that a good approach?Do you guys have any tips on the box design - resources on the net maybe?Or, if I get someone to do it, what do I look for, a "packaging designer", is that a thing?

author: Kean
author_rank: Unknown
timestamp: February 24, 2021, 01:41:54 pm
content: Quote from: simonlasnier on February 24, 2021, 09:38:07 amYes, you can make compartments to separate and protect the product components by folding and layering often just the one sheet of cardboard. But if your product has any significant mass to it, then you need a carefully considered and tested design, or to should use foam.QuoteGoogle images or Pinterest. Even better, start looking at product packaging you have in the cupboard at home, or go shopping and study the boxes things come in. Especially anything from Dyson!QuoteAbsolutely it is. AKA packaging engineer. Packaging design is even a sub category on Fiverr, but mostly for the graphical design side.

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 24, 2021, 06:03:37 pm
content: Thanks Kean!Yes I actually just started checking FiverrAnd yes great tip about looking at boxes at home, I have tons of similar devices (in size and weight) than the one I am making, so I will check how they are made.One thing that comes to mind: what are the requirements of these "box factories" - it's card board so I guess they can cut and bend pretty much any way anywhere?

author: phil from seattle
author_rank: Super Contributor
timestamp: February 24, 2021, 09:16:04 pm
content: I'm somewhat down the path you are on. Have shipped about 250 units so far. Packaging is an area that I wish I had spent more time on at the beginning. Depending on how "sexy" you want your packaging to be, you can spend a lot of money. But even simple sturdy shipping boxes and padding can cost you close to a euro/dollar.Some lessons learned -Avoid the lowest priced solutions. What may seem expensive often works in your favor by minimizing problems to deal with. Remember, the first impression your customer has is from the packaging.Shipping labels: do not go cheap. Worst thing is a label falls off - lost revenue and unhappy customer. I had one batch that simply would not stay on - the edges would curl up after a few minutes. Don't bother with laser printer labels, too much time and fuss. Get an electrostatic label printer and roll or fanfold labels. A couple hundred dollars/euros but well worth it. I have a Rollo that I wish I had started with. Fast print, professional looking labels and very small footprint. Printing and labeling the box is about a 20 second operation.Shipping boxes: get ones that minimize exposed edges. My first set was pretty poor - 150x100x50mm and had an exposed 150mm edge. I wound up taping it to avoid it catching on things - extra work and a less professional look.Presentation packaging. This is where you can spend a lot of money. Keep it simple. You have to decide how much you want to put into it. For 1000 units, fixed costs can be significant, per unit.Think about packaging and shipping work flow. Your first 10 units, you will not mind it taking longer to do. After a couple of hundred, even a few seconds starts to add up. I've got it down to less than 3 minutes to package and label the product. Early on, it was about 10 minutes.

author: SMTech
author_rank: Frequent Contributor
timestamp: February 24, 2021, 11:49:25 pm
content: Depending on what your product is a box supplier may well have a stock box that works without customisation. One of our customers uses a box that is intended to ship 3.5" disk drives, its basically a sleeve that hold a an insert of foam backed card, super simple to pack and if you wanted it to be pretty you could add a decorative sleeve/sticker. By contrast another who was launching a small piece of consumer electronics got a proper bespoke design that was almost like origami, came as a flat sheet of printed card stock and folded up into a very sturdy cube very much like most phones seem to ship in these days.Our own products are commercial controls, typically the person opening the parcel is the installation engineer so we don't have bespoke packing or presentation boxes and nobody cares.. all depends on your market.

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 25, 2021, 09:17:50 am
content: Thank you bothMy market is B2C and it's definitely important to "impress" the customers when they receive the box. I'll have a quick look at stock boxes, but we did the same for the enclosure, spent a lot of time trying to use a stock enclosure which could fit - and ended up design our own metal enclosure: it's simple, 2 pieces of metal bent and powder coated with silkscreen, and can be made very cheapSo my guess is the same for the card board box, as long as we stick to 100% cardboard: once we have the design, it should not be expensive for a company to print on a piece of cardboard, then cut and bend with a machine to make a really nice looking box.Just FYI for the box design I actually found that website freelancer.com which sounds very promising - looks like a more professional version of fiverr@phil:* for the shipping I intend to use DHL and make an arrangement with them so they take care of the taxes and everything (I don't want my end-customers to receive the package with a note saying they have to pay import tax) - I guess I'll let them handle the labels* Not sure what you mean by exposed edges? My device is rectangular and the box will be as wellAlso, what do you guys think about the packaging for shipping? Normally when I order a device from a shop the devices are "double-packed", i.e.: device -> into manufacturer's box (pretty with the name and stuff) -> into a big brown cardboard box with loads of bubble wrap/stuffing to protect it

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 25, 2021, 12:59:47 pm
content: Thank you blueskull that would be great!I am not in a hurry - and would love to have a few names of companies like thatJust FYI I am trying to get the PCBA house, the case manufacturer (who will assemble the product, put it in the box and ship it so everything will be sent there), and the packaging factory all close to each other to limit shipping costs from one to another. Right now the PCBA house and case manufacturers are about a 30min drive away, right between Shenzhen and Dongguan.

author: HwAoRrDk
author_rank: Super Contributor
timestamp: February 25, 2021, 01:03:08 pm
content: Quote from: simonlasnier on February 25, 2021, 09:17:50 amThere will be two reasons why boxes are double-packed:The manufacturer's packaging is not designed for shipping (i.e. just to afford some basic protection or make it easy to handle, and/or look pretty on a store shelf), so the shipper must add packaging or the product will be damaged.Or, for security or obfuscation - the manufacturer's packaging may be perfectly adequate for shipping on its own, but the product is conspicuously high value or desirable, so covering it avoids anyone handling the packaging from knowing what's inside.If you're designing your own packaging for your product that will not be resold by a third party, and shipped directly to the customer, you might as well design packaging capable of being shipped on its own. But that's assuming presentation is not the highest priority.

author: m98
author_rank: Frequent Contributor
timestamp: February 25, 2021, 02:31:49 pm
content: Instead of cardboard for product packaging, you also could go metal. A nice tin can with custom embossing and foam inlay will look really impressive, while not costing too much more than a custom cardboard box in small volumes.Something like this:http://1a-dosenshop.de/quadratische-blechdosen/silbermatt-edition-quadratische-stulpdeckeldose-120x120x35mm.html

author: phil from seattle
author_rank: Super Contributor
timestamp: February 25, 2021, 06:47:50 pm
content: Quote from: m98 on February 25, 2021, 02:31:49 pmInteresting point. A number of companies create branded containers - Altoids, is a good example - that advertise their company and/or product long after the product is consumed/removed. I have a number of jars that I use for storage in the kitchen that remind me where they came from every time I look at them.

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 26, 2021, 07:51:39 am
content: Ha ha true, who doesn't have one like that at homeBut in an electronics device case they should not eat my device (I hope) so I they should have the device itself to remember it)Also price is still a very important factor so if I can have smth that looks good in cardboard I am sure it can be a lot cheaper.@HwAoRrDk: interesting thoughts thanks. My business is music gear, and the reseller I was thinking about was Thomann.de, they always double-pack. But so if I want to avoid it there should not be much writing on the outside of the packaging you say?

author: Mike_GFY
author_rank: Newbie
timestamp: February 26, 2021, 02:08:07 pm
content: for the customized cardboard box design, for main cost for the beginning cost is the die-cut tooling cost which is not high, 50bucks i think for the small flight box i did before. And if you have the box vendor, you can show them how you want to place the boards and case in the box and your requirements, i think they will help you design the box. you can use the anti-static seal bag for the PCBA and the bubble bag for the case proection. To hold the parts in the box steady, you can either design a holding cardboard inside the box or customized foam or even blister tray to hold them. I will suggest the card board because the box vendor can do it for you also. There different thickness of the cardboard you can choose for the box and the cost will be different. and you can do the printing on the box also.If you want to design the gift box, there will be many different style, like mat finish, like foil feeling, the gift box vendor will get you more details.so i think 1.get a box vendor 2.tell him how you want to place the parts and requirements like box size 3. ask him to design the die-cut for you 4.put your graphics design on the box 5. he will make the box for you. That's all my idea.

author: Saimoun
author_rank: Frequent Contributor
timestamp: February 26, 2021, 03:05:41 pm
content: Thanks Mike I agree! Only have to find a box vendorI'll ask the ones I found on alibaba

author: Saimoun
author_rank: Frequent Contributor
timestamp: March 09, 2021, 08:02:16 am
content: Hey blueskull, that is great!What is OSHW - Open Source Hardware?Actually I spoke to my PCBA house and they said they are happy to do the assembling and packaging for $10/hour. So I will send the unassembled case, the button caps and knobs, the screws and the cardboard packaging to them, they will assemble it all and ship it to my customers directly.So all I need is a company that can fabricate and print the packaging - can you send me the name of the shops from HQB street? I would also be happy to talk to your friend doing OSHW business if I can have her contactThanks!