Structural Design and Performance Verification of PLA Modular Express Boxes

ZHANG Hanyue; XIAO Yingzhe; FANG Jingli; CHENG Yuhang; DUAN Dongjun; ZHANG Zhenghang; HUA Guangjun

doi:10.19554/j.cnki.1001-3563.2026.09.031

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Packaging Engineering ›› 2026, Vol. 47 ›› Issue (9) : 296-305. DOI: 10.19554/j.cnki.1001-3563.2026.09.031

Green Packaging and Circular Economy

Structural Design and Performance Verification of PLA Modular Express Boxes

ZHANG Hanyue, XIAO Yingzhe^*, FANG Jingli, CHENG Yuhang, DUAN Dongjun, ZHANG Zhenghang, HUA Guangjun

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Abstract

To promote the green and circular development of packaging and address the issues of non-degradability and difficult recycling of express packaging waste, the work aims to provide innovative solutions for the sustainable development of express boxes. An integrated structure-function design for a recyclable express box was carried out based on circular design and other methodologies. A novel slide-rail type detachable hinge structure was designed, achieving modularity and panelization by engaging the hinges with sliding grooves on the box sheets. Experimental tests were conducted to evaluate the mechanical properties of PLA sheets, along with folding fatigue tests on the hinges and compression and drop tests on the complete box. Static simulation analysis was performed on both the hinge and the complete box structure. The experimental results indicated that the PLA sheets demonstrated good plastic deformation capability. The hinges passed a 20 000-cycle folding test without damage. The average compression resistance of the complete box was approximately 3 362.6 N, which was about 1.8 times that of a corrugated cardboard box of the same size, and it passed the six-face, three-edge, and three-corner drop test. Finite element simulation results showed that the stress distribution on the hinges in both folded and unfolded states was uniform, with a maximum stress of about 60 MPa. Under a 3 500 N compressive load, the maximum stress on the complete box was 44.2 MPa, with no severe stress concentration, confirming a reasonable structural design. This work successfully integrates PLA materials with foldable functionality, establishes a complete system from material test and structural design to performance verification, applies finite element methods in packaging engineering practice, and forms a closed-loop research framework of "design-experiment-simulation-evaluation-discussion", further providing a theoretical basis and technical support for the development of green packaging and offering valuable insights for the transition of express box design and application toward sustainable development.

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polylactic acid (PLA) / recyclable express box / modular design / mechanical properties / green packaging

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ZHANG Hanyue, XIAO Yingzhe, FANG Jingli, CHENG Yuhang, DUAN Dongjun, ZHANG Zhenghang, HUA Guangjun. Structural Design and Performance Verification of PLA Modular Express Boxes[J]. Packaging Engineering. 2026, 47(9): 296-305 https://doi.org/10.19554/j.cnki.1001-3563.2026.09.031

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