Methods and apparatus for manufacturing fiber-based, foldable packaging assemblies

1. A packing system for shipping original design manufacturer (ODM) boxes, the system comprising:

a plurality of corner sets, each vacuum formed from a fiber-based slurry and each comprising at least two fiber cushions;

a plurality of end cap sets, each comprising two opposing corrugated sleeves; and

a graphical guide comprising an end cap selector and a corner selector;

wherein:

the graphical guide is configured to allow a user to: i) compare an ODM box to the end cap selector to thereby select one of the plurality of end cap sets; and ii) compare the ODM box to the corner selector to thereby select one of the plurality of end corner sets;

each sleeve comprises a plurality of height score lines, a plurality of width score lines, and a support feature to stabilize the sleeve during folding;

the plurality of corner sets comprises at least a first corner set having four fiber cushions of a first size, and a second corner set having four fiber cushions of a second size, wherein the first size is different from the second size; and

the plurality of end cap sets comprises at least a first end cap set having two sleeves of a first size, and a second end cap set having two sleeves of a second size.

2. The system of claim 1 , wherein:

the plurality of corner sets further comprises a third corner set having four fiber cushions of a third size, and a fourth corner set having four fiber cushions of a fourth size; and

the plurality of end cap sets further comprises a third end cap set having two sleeves of a third size.

3. The system of claim 1 , wherein:

the end cap selector comprises a first zone corresponding to the first end cap set, and a second zone corresponding to the second end cap set; and

the corner selector comprises a first guide line corresponding to the first corner set, and a second guide line corresponding to the second corner set.

4. The system of claim 3 , wherein:

the plurality of height score lines are configured to allow a user to select a particular one of the height score lines based on the height of the ODM box, and to fold the sleeve along the selected height score line; and

the plurality of width score lines are configured to allow a user to select a particular one of the width score lines based on the width of the ODM box, and to fold the sleeve along the selected width score line.

5. The system of claim 4 , wherein the support feature comprises a plurality of tabs, each corresponding to a respective width score line.

6. The system of claim 4 , further comprising a generally u-shaped corrugated screen protector.

7. The system of claim 6 , wherein the screen protector comprises an array of vacuum molded fiber feet.

8. The system of claim 4 , wherein:

each of the first size corner cushions comprises a first width corresponding to a first one of the width score lines along which the end cap is to be folded; and

each of the second size corner cushions comprises a second width corresponding to a second one of the width score lines along which the end cap is to be folded.

9. The system of claim 8 , configured to be assembled such that:

the screen protector is disposed over the top of the ODM box, with the array of feet adjacent a front surface of the ODM box;

a top corner of each sleeve, when folded along the selected width score line and the selected height score line, mates with a corresponding top corner of the ODM box, with one of the selected corner cushions disposed therebetween; and

a bottom corner of each sleeve, when folded along the selected width score line and the selected height score line, mates with a corresponding bottom corner of the ODM box, with one of the selected corner cushions disposed therebetween.