Fragile Item Packaging Calculator

Cushioning thickness from product weight and drop height.

Product weight (lbs)

Product fragility (G)

Expected drop height (in)

Foam max compression ratio

Cushion bearing area (sq in)

Tab to move between fields

Recommended cushion (in)

1.25

Peak G with recommended pad

Minimum thickness (in)1.02

Safety margin %18

Static loading (PSI)0.25

Impact energy (in-lbs)450

Required deflection (in)0.61

Total foam volume (cu in)150

How to Use This Calculator

Enter product weight (lbs) and fragility level (G rating from product fragility testing).
Enter drop height (inches) expected in the distribution environment.
Read required cushioning thickness (inches) for the specified foam type and fragility.
Review foam cushion curve data — select foam density that peaks G below the product fragility level.
Validate packaging design with ISTA 2A or equivalent test series before releasing to production.

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