Moulded-Pulp Packaging: A Straightforward Method for Quickly Designing, Manufacturing and Testing Complex Shapes for Crash Protection Pads

Moulded-pulp packaging stands poised to replace traditional polystyrene packaging due to its eco-friendly nature and recyclability. However, optimizing the protective pins within moulded-pulp packaging has been a challenge, hindering its widespread adoption. This paper presents an innovative approach to swiftly and cost-effectively optimize pin shapes, which is crucial for enhancing impact resistance. We hereby propose a simple try and error pin optimization methodology by utilizing an hand-moulded pulp recipe and PLA 3D-printed moulds to rapidly craft tailored cardboard pins. The validation of the material fabrication was carried out with static characterization and the classification of the homemade moulded-pulp pins with impact testing analysis. This exploratory project demonstrates the feasibility of this approach, laying the foundation for future advancements in moulded-pulp packaging design.