BCI Knoxvilleās initial design for LeMond was a mix of corrugated and foam. Market feedback from LeMond customers was positive. The packaging was āinnovativeā and offered an unprecedented unboxing experience while protecting the ebikes valued at $5,000. BCI was then challenged to remove all foam from current packaging.
We were able to remove all but one piece of foam by adding in strategically placed protective tape. We designed a 1-piece DC to protect the bike during shipping and to maintain the high-end unboxing experience.Ā
The foam that was removed was valued at $75-$100 depending on the bike style and replaced with $30 worth of corrugation.Ā
