Structural Packaging Design Course

Lesson 1 • The Role of Packaging in Commerce

Defines packaging's four core functions: containment, protection, communication, and convenience. Establishes why structural decisions drive cost and consumer experience.

Lesson 2 • The Structural Design Process

Maps the end-to-end workflow from brief to production-ready dieboard. Shows how each phase connects to downstream manufacturing decisions.

Lesson 3 • Material Categories and Properties

Surveys paperboard, corrugated board, plastics, glass, metal, and flexible films. Links material properties to structural performance requirements.

Lesson 1 • Dieline Quality Checks and Handoff

Establishes preflight checks for open paths, overlapping lines, and missing dimensions. Clean handoff files reduce supplier queries and tooling delays.

Lesson 2 • Allowances, Tolerances, and Clearances

Quantifies material thickness compensation, machine tolerances, and product clearances. Applying correct allowances prevents fit failures in production.

Lesson 3 • Digital Dieline Tools and Workflows

Introduces vector-based CAD and packaging-specific software for dieline creation. Efficient digital workflows reduce revision cycles and file errors.

Lesson 4 • Dieline Anatomy and Layer Conventions

Breaks down cut, crease, perforation, and glue lines with their standard layer assignments. Correct layer use prevents costly tooling errors.

Lesson 1 • Carton Style Classification

Categorises cartons by closure type, erection method, and panel configuration. Classification guides style selection based on product and production requirements.

Lesson 2 • Structural Reinforcement Techniques

Applies double-wall panels, gussets, and internal partitions to increase carton rigidity. Reinforcement choices affect material cost and stacking performance.

Lesson 3 • Panel Geometry and Blank Layout

Calculates panel dimensions from product dimensions using standard formulas. Accurate blank layout minimises material waste and ensures correct finished size.

Lesson 4 • Closure Mechanics and Locking Features

Designs tuck flaps, dust flaps, and mechanical locks for secure closure. Closure geometry must balance ease of opening with tamper resistance.

Lesson 1 • Cushioning and Product Protection

Designs internal fitments, pads, and void-fill systems to limit product movement and shock. Protection level is matched to fragility ratings from drop and vibration data.

Lesson 2 • Standard Box Styles and Codes

Introduces internationally recognised box style codes for regular slotted, full overlap, and die-cut styles. Standard codes enable unambiguous communication with converters.

Lesson 3 • Corrugated Box Testing and Validation

Applies standard compression, drop, and vibration tests to validate box performance. Test results guide design revisions before production commitment.

Lesson 4 • Compression Strength Calculations

Applies stacking load formulas and safety factors to size box walls for warehouse conditions. Calculations account for stacking height, humidity, and storage duration.

Lesson 1 • Blister and Clamshell Packaging

Designs blister cavities and clamshell hinges for retail display and product security. Cavity sizing and hinge geometry affect sealing reliability and consumer access.

Lesson 2 • Thermoforming Design Principles

Applies draft angles, radii, and draw ratios to design thermoformed trays and clamshells. Correct geometry ensures clean release and consistent wall thickness.

Lesson 3 • Tray and Insert Design

Creates moulded pulp, corrugated, and thermoformed trays that position products precisely. Insert geometry must accommodate product variation and assembly speed.

Lesson 1 • Fitments, Zippers, and Closures

Integrates spouts, zippers, and valves into flexible structures without compromising seal integrity. Fitment placement affects filling speed and consumer usability.

Lesson 2 • Pouch Styles and Geometry

Covers pillow, three-side seal, stand-up, and quad-seal pouch constructions with their dimensional rules. Pouch style selection balances shelf presence, fill volume, and machine compatibility.

Lesson 3 • Flexible Film Laminate Structures

Explains how layers of film, foil, and coatings are combined to achieve barrier and mechanical targets. Layer sequence and adhesive selection determine delamination resistance.

Lesson 4 • Machinability and Runnability

Evaluates film stiffness, coefficient of friction, and static charge for high-speed machine compatibility. Poor runnability causes line stoppages and seal defects.

Lesson 1 • Lightweighting and Material Reduction

Applies caliper reduction, panel optimisation, and geometry changes to reduce material use. Lightweighting must preserve structural performance under distribution stresses.

Lesson 2 • Design for Recyclability

Applies recyclability guidelines to eliminate incompatible materials, inks, and adhesives. Designs are evaluated against material recovery facility sorting capabilities.

Lesson 3 • Sustainable Material Selection

Evaluates recycled content, renewable sourcing, and end-of-life pathways for packaging materials. Material choice must balance environmental impact with functional performance.

Lesson 4 • Measuring and Reporting Environmental Impact

Introduces carbon footprint, water use, and packaging intensity metrics for design comparison. Quantified metrics support business cases for sustainable redesign.

Lesson 1 • Manufacturing Processes for Packaging

Covers die-cutting, folding-gluing, thermoforming, and converting processes relevant to structural packaging. Understanding manufacturing constraints prevents unproducible designs.

Lesson 2 • Supplier Qualification and Briefing

Defines supplier selection criteria, technical brief content, and qualification testing requirements. Clear briefs reduce misalignment and accelerate supplier approval.

Lesson 3 • Tooling Design and Management

Explains steel-rule die construction, cutting formes, and thermoform mould specifications. Tooling decisions affect lead time, cost, and design change flexibility.

Lesson 4 • Project Timeline and Risk Management

Builds packaging project timelines with critical path milestones and risk mitigation plans. Timeline discipline prevents late launches caused by tooling or approval delays.