In this lab, students will explore the world of packaging engineering by learning how everyday items are protected on their journey from production to the consumer. They’ll uncover the science behind cushioning and impact, seeing how different materials and structures absorb force.
Along the way, they’ll connect concepts from physics, material science, sustainability, and even marketing to understand the full picture of packaging design. Finally, students will take on a hands-on challenge: creating their own package to protect a potato chip, testing its durability, and evaluating how well their designs balance protection, cost, and environmental impact.
Students will:
- Analyze real-world packaging challenges and apply critical thinking to develop effective solutions
- Explain the engineering design process as it applies to creating protective packaging
- Investigate how material properties and structure influence packaging performance
- Collect and analyze data from impact and drop tests to evaluate package effectiveness
- Balance multiple design constraints, including cost, protection, and sustainability
- Communicate and compare results with peers to refine their packaging designs
Classroom Tools & Resources
Get access to all of the presentation materials, workbooks and resources to run the Packaging Engineering lab in your classroom.
Lab Intro Videos
Get our engineer’s introduction to the lab topic and learn more about the lab activity.
Teacher Guide (doc to come)
Pre-work, instructions and troubleshooting advice.
ViewStudent Workbook (doc to come)
Questions and assessments from the lab presentation.
ViewAbbreviated Student Worksheet (doc to come)
A worksheet containing major student lab activities.
View
Engineer’s Presentation
Full lab presentation presented by our engineers.
ViewMeet the lab intro host
Pat Marshall
Staff Engineer
Pat earned a Bachelor of Science in Civil Engineering from the University of Illinois at Urbana-Champaign, where he was a student-athlete in Track & Field/Cross Country and Rugby. He also served as Project Manager for the university’s Concrete Canoe Team for two years, leading engineering efforts and team coordination resulting in qualification to Nationals.
Following graduation, Pat joined the Peace Corps and was stationed in Lesotho, a mountainous region in southern Africa. There, he and his team were responsible for designing and constructing pedestrian bridges across rivers that were otherwise impassable for months at a time, providing critical access for local communities.
Upon returning to the U.S., Pat worked on a range of civil engineering projects—from hydraulic analysis for wastewater treatment facilities to designing highway on-ramp vertical curves. After several years in the industry, he discovered a passion for education and transitioned into teaching and coaching at the high school level.
Since 2003, Pat has taught physics, engineering, and computer science at St. Patrick High School and Benet Academy. Beyond the classroom, he has coached track and field, Science Olympiad, and robotics teams, combining his technical expertise with a deep commitment to student development.
Pat earned a Bachelor of Science in Civil Engineering from the University of Illinois at Urbana-Champaign, where he was a student-athlete in Track & Field/Cross Country and Rugby. He also served as Project Manager for the university’s Concrete Canoe Team for two years, leading engineering efforts and team coordination resulting in qualification to Nationals.
Following graduation, Pat joined the Peace Corps and was stationed in Lesotho, a mountainous region in southern Africa. There, he and his team were responsible for designing and constructing pedestrian bridges across rivers that were otherwise impassable for months at a time, providing critical access for local communities.
Upon returning to the U.S., Pat worked on a range of civil engineering projects—from hydraulic analysis for wastewater treatment facilities to designing highway on-ramp vertical curves. After several years in the industry, he discovered a passion for education and transitioned into teaching and coaching at the high school level.
Since 2003, Pat has taught physics, engineering, and computer science at St. Patrick High School and Benet Academy. Beyond the classroom, he has coached track and field, Science Olympiad, and robotics teams, combining his technical expertise with a deep commitment to student development.
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