Objective To improve the outer packing structure cushioning performance of the electric switch, to reduce the logistics cost, and to minimize the damage occur during transport and storage process. Methods The choices of packaging materials including outer and cushion materials and whole packaging structure designs were introduced according to the properties of product in this paper; and drop test was carried out for the whole packaging. The logistic cost of new packaging was confirmed to reduce through reducing the packaging size and weight, and the costs of raw materials and the logistic costs were compared between the original packaging and the new one. Conclusion Optimal design of new packaging was indeed improved in the cushion performance, and the new packing comprehensive cost was reduced by 8. 11% compared with the original packaging cost. The optimum design scheme for electric switch packaging is thus feasible.