Structural design & product development

Engineering is where an idea becomes manufacturable. Dimensions, creases, locks and tolerances are decided here, and mistakes are found cheaply rather than expensively.

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Sequence of work

Measuring the product and defining protection and handling requirements.
Dieline with creases, cut lines, bleed and glue areas.
A physical mock-up tested with the real product.
Adjustment, approved specification and handover to production.

Tolerances and material thickness

Board thickness affects both internal and external dimensions, especially across multiple folds. We always state which dimension applies and place tolerance where the product meets the packaging. Without stated tolerance, fit becomes arbitrary between production runs.

Mock-up and verification

A mock-up shows what a screen cannot: whether the lid binds, whether the insert lifts with the product, whether the box feels empty or too tight. Where transport requirements exist, drop or vibration testing can be carried out at a supplier or test institute. Results are documented in the specification.

What is handed over to production

Approved dieline, material specification, print and finish instructions, tolerances and packing instructions. The supplier produces against this document set, and VyPack inspects the result against the same documents.

Material, structure and finish in detail

We review board quality, thickness, fit, print technique and finishing with you and turn it into a specification a supplier can produce against.

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FAQ

Frequently asked questions

Can you engineer from an idea or sketch?: Yes. We need product dimensions and weight, then we produce a dieline and mock-up.
How many sample rounds are usually needed?: One to two for standard structures, more for special packaging or new tooling.
Do we own the structure?: Documents produced for your project are used for your production. Terms follow the project agreement.
What does a mock-up cost?: Physical samples from approx. SEK 1,500 depending on structure, material and finish.

Custom insertsA custom insert does two things at once: it keeps the product still and decides the order in which the unboxing happens. Both come down to millimetres.Read more Special packagingWhen a product is heavy, irregular or fragile, standard formats rarely solve the problem. Then the work starts in the structure rather than in a catalogue.Read more Consultation & adviceMost expensive mistakes in packaging projects are made before anything is ordered: the wrong format, the wrong material or a volume that does not suit the production method. Advice exists to avoid exactly that.Read more Production & supplier networkVyPack owns no factory. We work with selected suppliers in Europe and Asia and choose the production site based on structure, volume, finish and lead time.Read more

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