A display can have correct outer dimensions and still sag when flute direction conflicts with the load path. The layout of a cardboard POS display cutting die must balance material yield against the structural behaviour of each part.

Map how load travels through the display

Product weight travels from shelf to side panels and then to the base. A thicker board alone will not fix a weak lock or support in that chain. Calculate the total product count and weight for each shelf.

The load path is drawn onto the drawing with arrows: from the shelf, which panel does the product weight come down to, which lock tab takes that load. The scheme shows which part wants heavier board or a double layer; adding thickness to the weak link in the chain rather than to the whole display saves both material and waste.

  • The load path is shown with arrows on the drawing; the weak link is marked.
  • Product count and weight are calculated separately for each shelf.
  • Reinforcement goes on the part that takes the load, not the whole display.

Do not rotate parts for yield alone

Rotating a part can improve sheet utilization while weakening flute orientation in a load-bearing panel. Body, shelf and support pieces do not necessarily need the same direction. Multipart tooling should preserve those differences.

A part rotated to gain yield reaches the die workshop in its rotated state, and the workshop may take that for a design decision. The flute direction of every part is therefore fixed with an arrow on the drawing; when the nesting software rotates the part the arrow rotates with it and the difference shows at once.

  • Flute direction is fixed with an arrow on every part; a rotated arrow reveals the error.
  • Direction is set separately for body, shelf and support parts.
  • A yield gain paid for by a load-bearing panel’s direction is given up.

Slots and creases change under load

Corrugated board compresses, changing slot clearance and crease behaviour. An overly tight connection crushes during assembly; an overly loose one can open under shelf load. Test with the real board close to the intended load.

Slot clearance is tried on the real material: a dry sample and a sheet from a damp store compress differently. A slot that is too tight crushes the flute during assembly, one that is too loose opens under load. If the sample is tried at a weight close to the target and left for a period close to its shelf life, the result represents the field.

  • Slot clearance is tried on the real material in real humidity conditions.
  • A tight slot crushes, a loose slot opens; both show on the sample.
  • The sample is tried at a weight close to the target and left to stand.

Create a simple repeatable load test

Place the assembled display on a level surface, distribute product evenly and observe shelf deflection, lock opening and panel buckling at set intervals. Record the result with board specification and photographs.

The load test must be repeatable: the same product count, the same standing time, the same photo angle. When shelf deflection is measured with a ruler and recorded, the repeat run talks in numbers instead of “it was fine last time”; when the board batch changes the test is briefly repeated.

  • Test conditions (count, time, photo angle) are kept constant.
  • Shelf deflection is measured and recorded with the board specification.
  • The test is briefly repeated when the board batch changes.

Application note

Send assembled dimensions, product count per shelf and board grade so flute direction can be assessed with die layout.

  • Use the current material and dimensions.
  • Compare a clean sample with the defective sample.
  • Record the decision with photographs and drawings.