Chapter 11

Shipping Optics
This chapter explains the current best methods for packaging optics
for shipment. The final step in manufacturing any optic or optical
system is shipping the product to the customer so that it arrives in
perfect condition.
A shipper has no interest in the project other than delivering the
package to the customer. The transfers during shipping can involve
several people who may toss, bounce, drop, mishandle, or misplace
the package. The goal of packaging is to prevent any damage by the
shippers.
The first step is to ask the customer what shipping method they
want. Is the package moving across town or across nations? Do they
want it shipped by truck, airplane, or ship? (In most cases, it will be
shipped by truck or airplane, or a combination of both.) During the
simplest method of shipment, a package may be handled by 3–5 people
and transferred using several trucks.
Most next-day or 2–3-day shipments are picked up in small trucks
and sent to a transfer station where the package is sorted. The package
is then loaded on a larger truck and sent to another transfer station at
an airport where it is sorted again. It is then placed on a plane and
flown to a very large, single-point transfer facility where it is combined
with thousands of packages and sorted once more. Then the whole
process is reversed as the package is delivered to the customer. At any
point during this process, the package can be subjected to conditions

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that could damage the optic, such as extreme high and low temperatures
during transfer at the airport or while waiting in the airplane or truck. It
can be exposed to rain, wind, snow, and ice. During handling it will be
dropped and/or crushed under other packages.
Review the following sections and use the method that best fits your
customer’s needs. It is important to consider the cost of packaging the
optic during the quoting process. If the optic is damaged, can it be
replaced? The cost of packaging increases with the value placed on the
optic, the project, and the customer’s expectations. Use the shipper’s
package tracking system and monitor it until the package is signed for
by the customer.

It is often worthwhile to add an extra piece of foam padding, use a box within a
box, order a shipping case from a catalog, or have a case specially designed
for shipping.

11.1 Cardboard, Plastic, and PET/G Boxes

There are many types of containers for shipping optics, but the
standard cardboard box is the most common. They are inexpensive
and readily available; however, the main concerns with cardboard are
loose paper fibers and exposure to moisture that will cause the box to
deteriorate. The boxes can be ordered with labels and simple locking
latches of wire or flaps that fold over to secure the lid. When using a
cardboard box, the optic needs to be wrapped in tissue and secured
with padding. Keep the cardboard box away from moisture. Use a
custom or catalog wooden box with a foam insert when necessary; it is
typically packaged within a larger cardboard box and wrapped with a
bubble-type wrap (as in Fig. 11.1).
A plastic box is a pre-molded box in both hard and soft plastic.
The box comes with a tight-seal lid and latch to secure against
opening. The optic is wrapped with tissue and contained in a foam
insert. If the optic has a critical surface, the optic can be secured on the
bottom and released when needed.

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 Shipping Optics 185

Figure 11.1 Cardboard shipping box using bubble wrap and pillows to secure the
box inside.

A PET/G container is a pre-molded package. This container comes

in various sizes and shapes; the package is matched to the shape of the
part, and it has angled or depressed contact areas. Only the edge or part
of the bevel area is in contact with the package. The molded bump in
the container secures the optic using pressure on the backside.

11.2 Cardboard Shipping Containers

For shipping optics, a corrugated cardboard box is the least-expensive
package choice. They are available in all shapes and sizes. Selection of
a box should be based on the size of the optic, type of shipping
method, and the environment that box will be exposed to. Use a
single-wall box for small and lightweight optics, and a double-wall
box for large and heavy optics.
The inside area of the box should be 2–4× larger in volume than
the optic (as shown in Fig. 11.2). Include the added volume of a tissue-
wrapped optic or a boxed one; this will allow for the extra amount of
packaging material needed to protect the optic. Label the wrapped
optics as required, with the part number, company name, etc.

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 186 Chapter 11

Figure 11.2 Cardboard shipping box showing the allotted space around the
container.

Packing material choices include newspaper, wrapping paper,

shredded paper, bubble-type wrap (Fig. 11.3), foam pellets, popcorn-
foam bag (popcorn inside a bag), spray foam, foam chunks or pieces,
foam cut to shape, or foam cutouts. Closed-cell foam for box or case
inserts works the best. It is available in different colors with antistatic
coating and cross-linked. Open-cell foam should be avoided, as it
will degrade over time and produce loose particles. The packing
thickness should be equal on all six sides to protect from shipping or
storage damage (Fig. 11.4). For multiple optics, use foam package
dividers or pockets in the foam; this is required to prevent the
wrapped optics from shifting and rubbing against each other. Note
that foam peanuts can be bagged to reduce foam dust, as shown in
Fig. 11.5.
Tape the top and bottom flaps of the cardboard box. For extra
protection, secure the flap edges with tape to prevent accidental
opening and dirt or moisture from entering the box. Label the box on
the top flap as required and label the sides “Optics—Handle with
Care.”

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 Shipping Optics 187

Figure 11.3 A box wrapped in bubble wrap and secured on the ends.

Figure 11.4 Proper placement of foam peanuts in a shipping box. Note the plastic
wrap around the foam box.

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Figure 11.5 To reduce foam dust, pack the foam peanuts in plastic food or trash
bags.

11.3 Clamshell Shipping Containers

Clamshell or molded containers are one of the best methods used to store
or ship optics. Clamshells were specifically developed as packaging for
laser optics and for use in clean rooms. Contents are secured in pre-
molded pocket shapes where only the edge or bevel of the optic is in
contact with the container.
Clamshells are ideal for use in cleanrooms because no fibers or
particles are introduced, and the container can be static discharged to
prevent any charge from coming in contact with electronic systems or
causing particles to stick to the optics. There is no contamination from
wrapping materials because they are not used with a clamshell
container.
Molded containers can be manufactured to specifications for size,
shape, and quantity per pack, and they can be made from many types
of thermoplastic materials. The container can have locking tabs to
secure and prevent accidental opening. High-quality containers can be
cleaned and reused several times.

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 Shipping Optics 189

Heat shrink and vacuum pack are other types of packaging that
hold optics. They secure the optic in place and keep the optic clean.
Always test any containment process on sample parts first.

11.4 Other Types of Shipping Boxes

The shipping box most often used for optics is cardboard. However, to
reduce cost and waste, reusable boxes may be a solution for multiple
shipments. There are many choices of materials and designs. A quality
wood box can be made to specification at a local shop or ordered from
a catalog.
The type of wood used for the box is important; plywood is a good
choice. Thickness is based on the weight and size of the optics: use the
2–4× rule for the size of the box. The bottom of the box should be
thicker than the sides. If the weight of the optics and box requires a
pallet or forklift to move, bottom skids should be added so that the
forks of a forklift can slide under. The top of the box is secured with
screws drilled into the side braces. Holders for paperwork can be
attached.
Catalog shipping cases are available. A molded-plastic shipping
case with hinges and latches (often used for shipping video cameras,
critical or expensive equipment) offers great protection. This type is

Figure 11.6 A layer of foam inserts positioned around the optic box.

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moisture proof and can be safely tumbled during shipping. The 2–4×
rule should be used for sizing the case.
Both wood and plastic boxes can have customized foam (closed
cell is recommended over open cell) cutouts made to order. The foam
cutouts should be designed to allow for wrapping material or internal
secondary containment; Fig. 11.6 depicts a viable arrangement. Some
allowance for compression is needed to prevent movement of the optic
during shipment. The foam should be thick enough to protect the
optic because the wrapping material does not have sufficient strength
to protect against hard impacts.

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