· 1 min read
The flat box
We shipped in tubes for a year. Here is the damage rate that ended that.
Toonhub
For the first year every figure shipped in a cardboard tube, because tubes are cheap and look good. About one in fourteen arrived with paint damage.
What changed
Flat box, figure disassembled, each part in its own foam bed. Cost per unit went up by about £2.40. The damage rate since the switch is under one in two hundred.
The part nobody warns you about
Disassembly means the customer assembles it, which means the join has to be good enough to be handled. That pushed us to redesign the neck socket on every figure in the series.