'The Impossible Box’

When GSE in America approached us with a challenge to build a reusable box that could safely transport two 75 inch rental screens, we knew straight away this was no ordinary build. These are huge displays with huge value riding on them. They also needed a solution that was lightweight, strong, shock absorbent, and reusable across multiple hire cycles. A flight case wasn’t suitable and a wooden crate wasn’t practical. What they needed felt like the impossible dream
a reusable box big enough, strong enough, and smart enough to do the job.

So we built it.

To give a sense of scale we even placed a standard 24 inch monitor at the front when we took the photos. It looks like a toy. That is how big this project really is.

From Impossible to Engineered Reality

The first obstacle was size. A single 75 inch screen is large enough. Two screens packed together in one reusable system pushed the design to the edge of what corrugated polypropylene construction can handle. The structure had to remain rigid and square even when empty and still be manageable for the rental teams lifting and loading it.

The second challenge was protection. GSE ship high value screens constantly across events and installations. Their kit gets moved by crews under serious time pressure. The box had to survive being pushed
pulled
slid
manhandled
and still protect the contents.

That meant a multi zone foam layout with a floating centre divide, pressure rated sidewalls, a dual depth foam base, and enough shock absorption to cope with hard landings without adding unnecessary bulk.

Designing the Internal Foam System

Inside the box is where the real engineering sits. The foam system is built from multiple layers of 30 kg foam, all precision cut to form a tight structural cradle. There are three key parts:

• The centre divide that keeps both screens separated and locked in place

• Sidewall blocks that take lateral impact

• Base supports that distribute weight evenly

• Top compression layer that closes the internal system and prevents movement during shipment

Every piece is removable, replaceable, and designed for the realities of rental life.

This is a box that gets used
not admired on a shelf.

Strength Without Weight

We used heavy duty black 10 mm polypropylene for the outer structure, reinforced with both mechanical fixings and internal returns. When you walk around it you realise this isn’t a typical reusable box. It behaves closer to a fully engineered crate while staying lightweight enough for two people to handle.

The side handles, reinforced corners, and pull tabs mean that even though it’s huge, it stays practical in the field.

A Giant in the Workshop

When the prototype stood up in the workshop for the first time it genuinely felt monumental. Everyone who walked past stopped. It is rare for a packaging project to become a talking point
but this one did.

That is why we deliberately photographed it beside a standard 24 inch monitor. It helps people understand the scale of what we were building. You don’t often see a reusable box that towers over desks.

Why GSE Chose Reusable Box

GSE needed:

• A long lasting solution

• Better protection than wood or flight cases

• Weight savings for easier handling

• Something that could be repaired or re foamed over time

• A box that could be shipped repeatedly without fail

We delivered all of that while keeping it fully recyclable at end of life.

The Outcome

The final product represents everything reusable packaging should be. Purpose built. Over engineered where it matters. Lightweight where possible. Repairable. Sustainable. And capable of doing what most people would say is impossible.

That’s the part we’re proud of.

This wasn’t just another job
this was solving a problem that no standard case or crate could solve. A reusable box for two monster sized screens that will now travel coast to coast across America with GSE’s rental fleet.

And it all started as the impossible dream.