To Gateway, an innovator in the PC industry, packaging matters. When shipping a computer, the company wants to be sure it will arrive just as it left the distribution center - undamaged. And in the 15 years that it took Gateway to reach $8.6 billion in annual sales, the company has learned how important delivering on that promise is to its customers.

Most of the company's products are built to order and shipped directly to customers through a package delivery service. With all the loading and unloading that occurs in transit, the interior packaging is the most crucial aspect of keeping the units safe from damage or puncture. In addition to offering protection, the packaging must be lightweight to minimize shipping costs.

Most recently, Gateway designed the customized packaging for its new Profile 3 all-in-one desktop computer. The company also had just 2 months to get it done.

Since a model of the Profile 3 was not readily available, two-dimensional CAD drawings were used in the development of a three-dimensional package design. The main component was molded expanded polypropylene foam (EPP), which provides a balance of performance properties that combine lightweight durability and shock absorption.

Special consideration was given to protecting the liquid crystal display screen and the L-shaped stand for that model. Also, Gateway wanted customer-friendly packaging.

"We want our customers to be able to intuitively disassemble the packaging and put their computer to immediate use," says David Drees, global packaging engineer.

Some minor adjustments were made to the initial design so the packaging would contour closer to the product to create a tighter fit. The packaging was redesigned as left and right end caps to ensure that the product was properly encased. Also, a nest in the ridge at the top of the cushioning was created for an accessory box. And the pre-packaged keyboard fits nicely into a space at the side of the carton.

The packaging was put to the test, surviving numerous instrumented drop tests. With the strength and resilience of the EPP interior packaging, each computer and its accessories now arrive unharmed at the customers' doorstep and desktop. "We're very happy with the level of performance of the packaging," says Drees.

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