Where Simulation Fits Between Design and Production

When a customer clicks Buy, the product journey has already begun.From that moment onward, packaging becomes responsible for protecting the product through handling, storage, transport, and delivery.

Yet, many packaging failures are still discovered after tooling, sampling, or even market launch. Cracks, leaks, deformation, and high return rates are often treated as logistics problems—when in reality, they are development-stage decisions catching up later.

This is where simulation plays a critical role.

In this guide, we break down the end-to-end packaging development roadmap and clearly show where simulation should sit—not as an add-on, but as a core validation step between design and production.

Step 1: Design Intent & Project Definition

Every packaging project begins with intent.

This stage focuses on defining:

• Product type and formulation behavior

• Brand positioning and shelf expectations

• Target markets and distribution routes

• Cost, sustainability, and performance targets

At this point, teams align on what the packaging must achieve, not how it will be built.

Clear intent prevents misalignment later in the project.

Step 2: Concept Design & Geometry Development

Once intent is defined, it is translated into structure.

This includes:

• Initial bottle or pack geometry (CAD)

• Capacity, proportions, and ergonomics

• Neck finish and closure selection

• Visual and branding alignment

At this stage, designs often look correct—but performance is still assumed, not proven.

Step 3: Material Definition & Assumptions

Before validation begins, material assumptions must be set.

Typical inputs include:

• Material type (PET, HDPE, PP, glass, etc.)

• Preliminary wall thickness distribution

• Expected mechanical behavior

These assumptions form the foundation for all further validation.If they are unclear or incorrect, testing outcomes become unreliable.

Step 4: Simulation & Virtual Validation (Critical Step)

This is where design meets reality.

Simulation allows teams to digitally test packaging before manufacturing, using real-world physics rather than assumptions.

Common simulation activities include:

• Drop simulations (base, side, angled impacts)

• Stress and strain analysis

• Identification of crack initiation zones

• Geometry–material interaction evaluation

What simulation reveals:

• High-stress zones invisible in CAD

• Weak points likely to fail in transit

• Areas where material is either insufficient or excessive

This step acts as a decision gate.Designs that pass simulation move forward with confidence. Designs that fail can be corrected early—when change is still easy.

Step 5: Design Optimization Based on Simulation

Simulation is not the end—it informs better design.

Based on results, teams can:

• Adjust wall thickness locally

• Refine base or shoulder geometry

• Improve load distribution

• Optimize material usage without over-engineering

These changes are data-driven, not subjective.

Step 6: Prototype Development

With a validated design in place, physical prototypes are developed.

This may involve:

• Rapid tooling or prototype molds

• Sample production

• Initial visual and functional checks

At this stage, the design is already de-risked, reducing surprises.

Step 7: Physical Testing & Compliance

Physical testing remains essential.

This includes:

• Drop and impact tests

• Transit and stacking trials

• Regulatory and compatibility testing

Simulation does not replace physical testing—it ensures that physical testing is confirmatory, not exploratory.

Step 8: Tooling & Production Readiness

Once performance is validated:

• Final molds are manufactured

• Process parameters are locked

• Quality benchmarks are defined

Because risk has already been addressed, late-stage changes are minimized.

Step 9: Production & Market Launch

The final outcome is packaging that:

• Survives the supply chain

• Reduces damage and returns

• Delivers a consistent unboxing experience

• Protects brand trust at scale

Customers may never see the simulation—but they experience the results.

Why Simulation Changes the Development Flow

Without simulation, teams often follow this path:Design → Prototype → Fail → Fix → Delay

With simulation embedded early, the flow becomes:Design → Simulate → Optimize → Produce → Perform

Simulation shifts packaging development from reactive correction to proactive decision-making.

Packaging, Decoded

Packaging success is not defined by how a product looks on shelf.It is defined by how well it survives everything before the shelf.

Simulation is the bridge between design intent and production reality—and when used correctly, it becomes a core part of smarter packaging development.

That’s packaging, decoded.