Modular, Sterile, Sustainable Packaging
ModBox
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Why?
- Design a packaging solution to better protect and ensure consistency of shipped single-use assemblies. A need to reduce defects on products shipped and provide a better end-user experience.
- Independently identified the problem and developed the concept. Worked with internal partners and vendor to bring it to life. (Shown below)
To the right is implemented solution that is costly, not recyclable, difficult to scale, and use open cell die cut foam. Also, it consumes significant storage volume since it comes assembled.
Concept Ideation
Concept assembly. Modeled and animated using SolidWorks.
How?
- Modular design is scalable and versatile for the highly customized products by utilizing and easy-to-assemble piece parts
- Flat-pack storage equates to 7.5x reduction in consumed warehouse space
- All parts are either compression molded or thermoformed with medical grade closed-cell foam, HDPE, and PET to easily scale throughput
- Sustainable materials
- Separation and securing tube sets (i.e. filters, clamps, etc.) while maintaining a protective barrier for the film.
- Presentable, easy unpack for customers
- Brand appeal with logo and thoughtful aesthetics
Result & Experience
The concept worked as intended only by introducing new vendors and materials to our manufacturing and business sector. During ISTA testing, there were some challenges with securing our largest 60lb assembly. The product stayed intact, but the separating foam wall did not prevent the tubing manifold from expanding. Visually, this was deemed not acceptable.
The solution did not launch, and I was recruited and promoted, by the Plant Manager, to Operations to implement lean process improvements. With more design work, this concept would be feasible.
This was my first project that I independently developed the business case, conceptualized, identified and collaborated with capable vendors, and pitched to senior & product management and external customers. It was an amazing learning experience, where I was able to foster my engineering design, sales, and entrepreneurial skills.