Custom Returnable Packaging Engineered For Your Part.

Upload CAD and explore a rack concept in our 3D Packaging Studio, then bring PSS in to engineer, prototype and build the production solution.

Launch 3D Rack Generator →Request Engineering Support

✎

Engineered solutionsBuilt around your part and process

✓

Prototype firstValidate fit, function and durability

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Production readyBuilt for long-term use and repeatability

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Launch supportReliable delivery and program support

Interactive Packaging Studio

Start with the part.
Build around it.

Try the current PSS 3D Rack Generator directly in your browser. Import STEP, IGES, STL, OBJ or GLB/glTF part data, test rack families, loading configurations, packout patterns, base styles and dunnage, then use the concept as a starting point for a real PSS packaging program.

Open the 3D Studio →Have PSS Engineer It

Live 3D Concept Workspace

Parametric rack concepts
Rack family · base · packout · dunnageConcept tool
Production engineering by PSS

Our Proven Process

01Part & process reviewWe learn your part, process and goals.

02Custom design3D CAD and concepts engineered to fit.

03Prototype & validationTest for fit, function and durability.

04Production buildPrecision fabrication and quality control.

05Delivery & supportOn-time delivery and ongoing support.

Packaging Solutions

Every solution is customized to your part, process and production volume.

Real examples are shown for clarity. Your project receives a fresh design, prototype and production quote.

Steel Bins

Custom or standard fabricated steel containers.

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Plastic Bins

Fixed-wall or collapsible bins, with optional custom dunnage.

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WIP Racks

Custom-designed for line-side presentation and material flow.

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Shipping Racks

Stackable, collapsible and heavy-duty transport systems.

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WIP Dollies

Mobile part presentation designed around operator handling.

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Plastic Totes

Standard or custom corrugated plastic totes with optional dunnage.

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Custom Dunnage

Fabric, foam, HDPE, urethane, rubber and mixed-material systems.

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Collapsible Options

Space-saving returnable packaging for improved return ratios.

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New in-house capability

Rapid Prototype Dunnage

Design it digitally. Validate it physically. PSS can now produce rapid prototype dunnage in-house to evaluate part fit, contact locations, clearances, loading access and concept geometry before committing to production tooling or fabrication.

Prototype components can be printed in TPU, PETG or PLA, making it easier to move from a Studio/CAD concept to a physical fit-check quickly.

Discuss Prototype Dunnage

TPUFlexible contact surfaces, cushioning, compliant locators and soft prototype interfaces.

PETGDurable rigid/semi-rigid prototypes for brackets, nests, guides and repeated fit checks.

PLAFast concept validation for geometry, spacing, loading trials and early design review.

Support beyond launch

Post Production Support

Our involvement does not end when production begins. PSS helps customers maintain, rework, repair and upgrade packaging throughout the life of the program—protecting the original investment and adapting fleets as parts and processes change.

Discuss Existing Packaging

Maintenance & RepairRoutine maintenance, weld repair, caster replacement and structural restoration.

Reworks & Engineering ChangesModify existing containers for revised parts, model changes or new process requirements.

Upgrades & RefurbishmentImprove dunnage, ergonomics, labeling, finishes, restraints and handling features.

Replacement DunnageReplace worn fabric, foam, plastic, rubber and production-intent dunnage components.

Fleet AdditionsBuild additional units from approved designs when program volume or routes expand.

Reuse & RepurposeEvaluate existing assets for economical conversion rather than complete replacement.

Company Presentation

Review our full-service capabilities, dunnage products, 3D design approach, prototype process, production support and program-management services in the 2026 PSS presentation.

The presentation also outlines our concept-to-production workflow, CAD capabilities, testing support, material-flow analysis, launch support, maintenance and ongoing program support.

View Presentation Download PDF

2026 Capabilities Presentation8 Pages →

Full-Service Packaging Support

Packaging Solutions & Systems supports programs from early concept and pack-density analysis through CAD design, production-intent prototypes, project management, production procurement and ongoing maintenance.

Design3D solid-model concepts developed around the part, ergonomics, material flow and transportation requirements.

PrototypeProduction-intent builds for fit, function, testing and refinement before production.

ProductionContainer procurement, dunnage tooling, fabrication oversight and quality support.

Program ManagementPlanning, budgeting, supplier selection, delivery management, launch and ongoing support.

Post Production SupportMaintenance, reworks, repair, upgrades, replacement dunnage and fleet additions.

Start Your Project

Upload your part, drawing, CAD model or packaging specification. Our engineering team will review your application and begin the design-and-prototype process.

Upload CAD, drawing, photo or current parameter sheet

STEP, IGES, PDF, DWG, JPG, PNG, spreadsheet or other relevant files.

Quote-based pricing: Every project is quoted individually based on current steel or resin pricing, prototype requirements, quantity, design complexity, dunnage, coating, freight and timing.

Already have packaging in service? Use the same form for maintenance, repair, rework, upgrades or replacement dunnage.

Request a Project Review

Fill out where applicable. Provide what you know and leave anything blank that does not apply or is still to be determined. Our team will help define the remaining requirements.

Where are you starting?

I need design + prototype

PSS will engineer the packaging, build a production-intent prototype and prepare it for approval. Prototype pricing includes design and engineering.

I already have an approved design / prototype

Upload the drawing, BOM or CAD data. We will estimate production using the known rack/bin weight and specifications.

Name

Company

Phone

Project & Product Information

Project / Job Type

Program / Model Year

Part Name

Part Number / Revision

Approximate Part Size

Part Weight

Material Type

Target Launch / Need Date

Math / CAD Data Available?

Physical Parts Available?

Container & Transportation Requirements

Packaging Type

Use / Flow

Transportation Mode

Ship-To ZIP / Postal Code

Approximate Fleet Size

Prototype Quantity

Production Quantity

Rack / Container Style

Base Size

Rack / Bin WeightEspecially helpful when you already have an approved design or prototype.

Desired Density

Minimum Spacing Between Parts

Delivery Media / Handling

Part Orientation

Similar Rack Exists?

Similar Rack Prints Available?

Similar Rack CAD Data Available?

Paint Specifications

Stencils / Stencil Specifications

Label Plate Size / Location

Other Design Requirements

Prototype, Ergonomic & Safety Requirements

Initial Prototype Welded & Painted?

Prototype Dunnage Scope

Dunnage Tooling Intent

Lift Assist Required?

Minimum Reach Height

Maximum Reach Height

Maximum Horizontal Reach

Other Safety / Ergonomic Requirements

Part Orientation, Sketch, Notes & Uploads

Part Orientation

Use the notes or upload a marked-up sketch showing operator side, critical locations and dunnage contact points.

Project Details / Notes

Project files

Drawing / CAD / specification

Part photo / existing rack photo

Additional file

Upload up to three files. Netlify's form upload limit is 8 MB for the entire submission. For larger CAD packages, include a secure sharing link in Project Details / Notes.

Calculate the preliminary range first. You can then submit the complete project request, estimate and files to PSS.

Preliminary project budget

Planning range

Medium confidenceMore project data improves accuracy.

Estimated production unit price—Per production unit

Production quantity—Estimated units

Estimated production program—Unit range × quantity

Design + prototype—Included when required

Estimated total project budget—

FreightPending destination

Estimated unit-cost makeup

Why this estimate?

Budget guidance only—not a formal quotation. The range is based on information supplied, standard PSS assumptions and similar historical programs. Final pricing requires engineering review, an approved design, supplier confirmation and shipment details.

Past Work. Real Solutions.

Every project starts with a different part and a fresh design.

Use these examples to understand our range—not to select a numbered product.

Production Program

Custom shipping-rack fleet

Production Scale

Repeatable fleet manufacturing

Steel Bin

Fabricated bulk container

Custom Dunnage

Protective part separation

Shipping Rack

Dedicated component restraint

Collapsible Bin

Space-saving returnable design

WIP System

Manufacturing-cell solution

Design Concept

Custom Returnable Packaging Engineered For Your Part.

Start with the part.Build around it.

Our Proven Process

Packaging Solutions

Steel Bins

Plastic Bins

WIP Racks

Shipping Racks

WIP Dollies

Plastic Totes

Custom Dunnage

Collapsible Options

Rapid Prototype Dunnage

Post Production Support

Company Presentation

Full-Service Packaging Support

Start Your Project

Request a Project Review

Planning range

Estimated unit-cost makeup

Why this estimate?

Past Work. Real Solutions.

Custom shipping-rack fleet

Repeatable fleet manufacturing

Fabricated bulk container

Protective part separation

Dedicated component restraint

Space-saving returnable design

Manufacturing-cell solution

Part-location study

Start with the part.
Build around it.