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Seeking advice: A client is currently using polyurethane P100-33E7 blocks to suspend a 33 lb device within a wooden crate. The current design includes a 6" buffer between the product and the crate on all sides (resulting in overall dimensions 12" larger than the product). The device is highly sensitive to shock and vibration, and this solution has been working well for them.

The product size will remain unchanged, but its weight will increase from 33 lbs to 121 lbs. The client wishes to retain the existing crate while redesigning the inner packaging. The new solution must withstand a 25 cm (~10") drop test while ensuring that shock transmission to the product does not exceed 4G.

Based on my understanding of polyurethane and the calculations available to me, it appears that this may not be a viable path forward. Are there alternative materials or solutions you would recommend?

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Kelli Schenck, CPP
The BoxMaker
Kent, WA
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Hi Keli,

Polyurethane for this should have a higher hardness of 80 to 90 Shore A, though the height of 25 cm is not that high but a higher density of 40-50 lbs/ft³ density range should be able to protect the 121 lbs product. A foam with a lesser compression will be able to protect the product.

You may go with EPS (Expanded Polystyrene), EPS should also give a good compressive strength, and it can be moulded as per the shape and it will be good for transit. You may have to conduct ECT and BCT.

I hope you considering an ASTM (ASTM D4169, D5276, D3332) standard for testing. An ISTA 1A with ASTM should give you a comprehensive result. 

Regards

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Nikhat Sayed
Printing & Packaging Engineer
Irvine CA
(714) 548-4383
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