Best Free & Open Source Packaging Design and Simulation Tools For Manufacturers

Packaging in manufacturing is not just about appearance. It is about fit, protection, cost, material efficiency, and survivability in real logistics conditions.

For manufacturers, packaging design software is used to:

• design boxes, inserts, trays, and protective structures
• validate fit against real products
• simulate loads, stacking, and transport stress
• reduce material usage and shipping damage

What qualifies as packaging design & simulation software

Included tools support at least one of the following:

• structural packaging design (boxes, inserts, fixtures)
• parametric sizing and fit
• material behavior or load analysis
• logistics-related simulation (stacking, compression, vibration)

Pure graphic design tools are excluded.

1. FreeCAD

Best for: Structural packaging design and parametric control

FreeCAD is one of the most practical open-source tools for packaging engineers. It allows parametric modeling of boxes, trays, inserts, and custom protective structures.

Common manufacturing uses include:

• fitting packaging to real product geometry
• adjusting dimensions for tolerance and variation
• designing reusable packaging and fixtures

With the FEM workbench, FreeCAD can also be used for basic structural analysis.

License: LGPL / Open Source

2. LibreCAD

Best for: 2D packaging layouts and dielines

LibreCAD is widely used for 2D packaging layouts, especially for:

• box dielines
• fold patterns
• flat layouts for cutting or die making

It is often used when packaging is produced by external suppliers who require clean 2D drawings.

License: GPL / Open Source

3. Inkscape

Best for: Packaging layouts and print-ready dielines

Inkscape is not an engineering tool, but it is frequently used for:

• dieline refinement
• multi-layer packaging layouts
• export to print and cutting systems

Manufacturers often pair Inkscape with CAD tools to finalize layouts.

License: GPL / Open Source

4. OpenFOAM

Best for: Advanced simulation of airflow and transport conditions

OpenFOAM is used in advanced packaging scenarios where airflow, cooling, or pressure matters. Examples include:

• ventilated packaging
• temperature-sensitive goods
• airflow through stacked containers

Trade-off:
Powerful but complex. Best for engineering teams.

License: GPL / Open Source

5. CalculiX

Best for: Structural simulation of packaging loads

CalculiX is commonly used to simulate:

• compression and stacking loads
• deformation of packaging under weight
• material stress in inserts or supports

It is especially useful for validating whether packaging survives transport and storage.

License: GPL / Open Source

6. Elmer FEM

Best for: Multi-physics packaging simulations

Elmer FEM supports structural, thermal, and multi-physics simulations. In packaging, it is used for:

• temperature effects on materials
• combined mechanical and thermal stress
• cold-chain packaging analysis

License: GPL / Open Source

7. KiCad (for packaging fixtures)

Best for: Packaging fixtures for electronics

While KiCad is an electronics design tool, it is often used to design:

• PCB trays
• ESD packaging
• electronic transport fixtures

Its mechanical exports integrate well with CAD tools.

License: GPL / Open Source

8. Salome

Best for: Pre-processing and simulation workflows

Salome is used as a pre-processing platform for meshing and simulation when working with:

• structural analysis
• CFD
• complex packaging geometries

It is commonly paired with CalculiX or OpenFOAM.

License: LGPL / Open Source

9. Blender (engineering visualization)

Best for: Visual validation and presentation

Blender is not a simulation tool, but manufacturers use it to:

• visualize packaging assemblies
• validate fit and handling
• create internal documentation and training visuals

License: GPL / Open Source

10. Parametric Packaging Scripts (Python-based)

Best for: High-volume, standardized packaging

Many manufacturers use Python scripts combined with CAD tools to generate:

• parametric box sizes
• insert patterns
• reusable packaging families

This approach is common when packaging must scale across many product variants.

License: Open / Custom

How manufacturers actually use these tools

Most manufacturers do not rely on a single packaging tool. A realistic workflow looks like this:

• CAD tool for structural design
• 2D tool for dielines and cutting layouts
• FEM or CFD tool for validation
• visualization tool for communication

Here is the comparison table of the solution 

Simulation is used selectively, not everywhere. It is applied when damage costs exceed modeling effort.

Final Takeaway

Free and open-source tools are fully capable of supporting industrial packaging design and simulation. They can model geometry, validate structural behavior, and support logistics-driven decisions. The limitation is not software capability. It is whether packaging is treated as an engineering problem or as an afterthought. Manufacturers who invest in structural packaging design reduce damage, material usage, and logistics cost without increasing product complexity.

About MDCplus

Our key features are real-time machine monitoring for swift issue resolution, power consumption tracking to promote sustainability, computerized maintenance management to reduce downtime, and vibration diagnostics for predictive maintenance. MDCplus's solutions are tailored for diverse industries, including aerospace, automotive, precision machining, and heavy industry. By delivering actionable insights and fostering seamless integration, we empower manufacturers to boost Overall Equipment Effectiveness (OEE), reduce operational costs, and achieve sustainable growth along with future planning.