Cheuk Yu • 2020 • Consumer Product Design
Designed to protect raw eggs from a six-foot drop
Built from a foldable sheet of cardboard
Triangular structure minimizes bending and redirects impact force
Spring-like cutouts reduce shock at contact points
Successfully passed real-world drop testing with all eggs surviving
Can be flat-packed for compact storage and easily assembled
Cardboard sheets, cardstock paper
Box cutter + cutting mat
Ruler, pencil, wood glue
Adobe Illustrator (for sketches and ideation drawings)
This project was a response to a design challenge: design a foldable container that protects raw eggs from a six-foot drop. The container I designed is made from a single sheet of cardboard, engineered to help redirect impact forces away from the eggs. The fully assembled structure is a rectangle with its cross-section shaped like a square with a cut-off triangular corner. Within this cross-section are three triangular-shaped sections, each of which helps redirect impact forces away from the eggs. These three triangular sections act as a shock absorption layer, redirecting the forces away from the eggs. The container has a capacity of three eggs, and each of them is sandwiched between two sheets of cardboard in the center "Pizza slice" area for even distribution, and to ensure that the eggs are stored in the very center of the container, with even spacing from the edge. This, combined with the direction of the cardboard grain, aligned parallel with the container to enable the container to flex and further reduce impact force like a crumple zone.
The result is a successful drop test from a height of six feet, while still allowing the container to fold flat for storage. This ended up being one of my favourite projects to work on, not just because of the challenge itself, but because it gave me a chance to experiment hands-on with structural design and materials in a practical way. There was a good amount of trial and error, but each attempt made me think more carefully about how the shape, layout, and material all need to work together to manage impact.
A selection of process and final-stage photos that highlight the progression and detail of this project. From initial preliminary work to refined finishes, these images provide a closer look at the build and design journey.
(Full image gallery available on separate page.)
A detailed explanation and demonstration of the foldable cardboard container designed to protect eggs from a six-footdrop. The video walks through the structure’s shock absorption system, layout choices, and the outcome of the drop test.