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Originally Posted by KarenH
Back to flat white boxes: have you seen the packaging for the new VEX kits? They look great in the store, and no doubt do a good job of protecting the delicate contents. But unpacking them without dropping the fragile parts everywhere almost requires a college degree. And, once the box is opened, you may need to purchase another type of container if you wish to keep your kit parts organized. 
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I cant believe how they can pack so little stuff into a styrofoam container and make it so that nothing moves and nothing makes noise.
I was working an A/V installation job at a container maker in Chicago several years ago. My eyes were opened to the science and technology that goes into making simple cardboard boxes. The design lab was bigger than the sales offices. Do you know that the boxes are cut with a drum that has blades sticking out of it in the shape of the box but compensated for the curvature of the drum? Once the material is cut then it goes through another process to "dimple" the cardboard where the folds are. As Karen suggested above, after the marketing people get done, the box still needs to be printed. This can take a number of different methods depending on how nice you want it to look. Can you imagine the cost of just the box those Gateway computers come in?