Our client needed a solution that would withstand multiple bumps and drops during shipping. Their boxes were being returned with heavy damage to the corners and the products inside. We decided to double-pack the original box inside a new, sturdier BoxGeek box and suspend it within, by adding foam protectors to the corners.
Our solution was to glue 3 black polyethylene foam corners together. Polyethylene foam is highly resilient and able to withstand multiple hits and bounce back to its original shape. This provided the cushioning needed to protect the package during shipment.
We placed the foam protection at each corner of the original box and placed it inside a larger box (not shown). The foam corners suspend the original box and move it away from any damage that could be caused by a sudden drop or from sliding around inside a truck.