A cushion design cannot be judged by foam thickness alone. Drop testing is the final proof that the pack will survive handling, and many overseas buyers request drop test records during inspection. Here is how the test works in practice.

Drop Height Follows Package Weight

Lighter packages are tossed higher during manual handling and courier sorting, so their drop height is set higher. Heavier packages move more slowly and use a lower height. As a rough guide: items under 5kg use 80 to 100cm; 5 to 20kg use 60 to 80cm; over 20kg use 40 to 60cm. Take the higher end for express courier or many transit handoffs.

What Gets Dropped

The standard sequence covers six faces, three edges, and one corner. You drop the top, bottom and four sides first, then the most load-bearing edges, then the weakest corner. After each drop, open the pack and check for cracking, deformation, loosening, or foam failure.

For screens and glass, watch corners and edges. For metal pumps and motors, focus on ports, shafts and mounting feet.

Adjusting After a Failure

Damage on a face means that side needs thicker cushion. Corner damage means thin corner foam. Damage from internal movement means a poor fit. Add foam on the affected side, switch to 17 or 23kg/m3 high-density foam, or reposition the product, then retest until all drops pass. CosMolar validates its foam-in-place packs with drop tests before bulk rollout. Call 400-812-0328 or visit https://www.cosmolar.com/.