Floor display with MULTIPURPOSE INSERT
This case study explores the design of a modular corrugated floor display engineered to merchandise three different products using a single structure. The objective was to achieve a snug, secure fit for each SKU while minimizing part count, tooling, and assembly complexity. I developed a universal display body paired with one insert that can be folded into three configurations to create distinct cavities. Prototyping and testing confirmed structural performance, stability, and ease of pack‑out.
Project Overview
deliverables
Create one standard floor display structure that works for three SKUs with different dimensions.
Ensure each product has a snug, damage‑preventing fit without excessive void space or overpacking.
Minimize part count to reduce tooling, assembly time, and inventory complexity.
solution
Developed a universal floor display body sized to accommodate the largest product in the family while maintaining structural integrity.
Engineered one insert design that can be folded in three different styles, each creating a unique internal cavity layout tailored to one product.
Insert design uses pre‑creased fold patterns and common locking features, so operators can quickly configure it for the required SKU without extra components.
outcome and impact
Successfully designed a single display system that holds all three products with a snug, secure fit.
Reduced part count by converging to one insert instead of three separate designs, lowering die‑cut tooling and inventory SKUs.
Simplified packing instructions and assembly, helping to reduce labor time and potential assembly errors.
Enabled flexible merchandising: the same display can be deployed across multiple promotions and products, improving reuse and reducing packaging waste.
