PSS logoPackaging Solutions & SystemsCustom packaging built around your partLaunch Studio
Custom automotive shipping rack

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
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Engineered solutionsBuilt around your part and process
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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
Part → concept → reviewSee how the Studio explores packout, dunnage and rack concepts.

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.

Custom fabricated steel bin
Explore Solution ›

Plastic Bins

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

Fixed-wall plastic bulk bin
Explore Solution ›

WIP Racks

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

Stacked work-in-process racks
Explore Solution ›

Shipping Racks

Stackable, collapsible and heavy-duty transport systems.

Custom steel shipping racks
Explore Solution ›

WIP Dollies

Mobile part presentation designed around operator handling.

Custom work-in-process dolly
Explore Solution ›

Plastic Totes

Standard or custom corrugated plastic totes with optional dunnage.

Handheld corrugated plastic tote
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Custom Dunnage

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

Rack with custom protective dunnage
Explore Solution ›

Collapsible Options

Space-saving returnable packaging for improved return ratios.

Collapsible steel container
Explore Solution ›
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 PresentationDownload PDF
PSS company presentation preview
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?
Project & Product Information
Container & Transportation Requirements
Especially helpful when you already have an approved design or prototype.
Prototype, Ergonomic & Safety Requirements
Part Orientation, Sketch, Notes & Uploads
Part Orientation
LR

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

Drawing / CAD / specification
Part photo / existing rack photo
Additional file
Files you send are treated as confidential and are shared only with the suppliers who need them to quote or build your packaging. Need an NDA in place first? Email Connor@PSSrack.com and we will sign one before you send anything. 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.

Preliminary range for planning purposes only. This is not a quotation and is not binding. Formal quotations are issued by PSS in writing and may differ. Freight is excluded unless a destination is provided.

Sends this estimate, your project details and any uploaded files to the PSS engineering team.

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 shipping rack fleet
Production Program

Custom shipping-rack fleet

Stacked production racks
Production Scale

Repeatable fleet manufacturing

Steel bin
Steel Bin

Fabricated bulk container

Custom dunnage
Custom Dunnage

Protective part separation

Automotive rack
Shipping Rack

Dedicated component restraint

Collapsible bin
Collapsible Bin

Space-saving returnable design

WIP system
WIP System

Manufacturing-cell solution

Design concept
Design Concept

Part-location study