Design a Packaging Insert From the Part Arrangement

Short answer: Calculate and approve the part arrangement first. Derive the insert's cavity grid from that arrangement, then check its outer size, height and weight in the container. Send the design to review with the part's STEP or STL file before you release it for manufacturing.

A packaging insert holds each part in a fixed position inside the container. Blisters, trays and dividers are common types. If the insert follows the calculated arrangement, the physical insert and the packing result agree.

Why the arrangement comes first

The arrangement sets the number of parts in each layer, their rotation and the gaps between them. The insert must repeat those positions. If you design the insert first, the insert and the packing result can disagree, and the container holds fewer parts than planned.

1. Fix the arrangement

• Set the gaps between parts. Each gap must leave room for a cavity wall.
• Set the clearance to the container walls and floor.
• Allow only the orientations that an operator can load reliably.
• Calculate the arrangement and review each layer in 3D.

2. Derive the insert from the arrangement

In Optipacker, insert cards marked From arrangement take their layout from the calculated part positions.

• Standard blister: the catalog sets the outer size, material and wall gauge. The arrangement sets the number of cavities.
• Divider: the arrangement sets the cells.
• Other insert types: a form starts with calculated sizes. The outer size comes from the container, and the cavity size is the part dimensions plus the clearance.

3. Check the insert in the container

• The outer size of the insert fits the inside dimensions of the container.
• The stack of inserts and parts stays below the container height, including any lid.
• The total weight of parts, inserts and container stays below the container's limit. Record the insert weight if the catalog has none.
• Operators can load and unload each cavity without tools.

4. Review and release the design

A derived insert gives cavity positions and sizes. The cavity shape that touches the part needs an engineering review. In Optipacker, you upload the part's STEP or STL file with the design. Optipacker engineers review the cavity design, propose changes and release the approved version with its technical drawing. Tool design and CAM need a separate handoff to the manufacturer.

5. Connect the insert to cost and purchasing

The insert is a line in the packaging bill of materials. Its quantity follows from the parts in each insert and your annual volume. A change in cavity count changes the number of inserts and containers, and it changes the investment. Optipacker creates purchase orders from the bill of materials after the required design is released.

Related

Read how to plan container packing from an STL file and how to choose an insert type, or discuss your part and insert requirements.