The Requirement
An Australian cat brand wanted a modular cat tree system that shipped flat to reduce freight and was easy for customers to assemble. They needed stable construction, custom plush colors, durable sisal scratching surfaces, and packaging that survived long-haul transit.
What We Did
- Structure development: engineered a modular flat-pack frame with shared connectors and a stable weighted base.
- Material selection: matched custom plush colors and confirmed sisal density for scratch durability.
- Sampling: simplified the assembly steps and hardware across two pre-production rounds.
- Packaging: designed a compact flat-pack carton with protective inserts and clear assembly instructions.
- Quality control: ran final random inspection against the approved sample and confirmed structural stability.
“Flat-pack shipping cut our freight cost significantly, and the assembly was simple enough to keep returns low.”
— Founder, Australian cat brand (name shared on request)The Outcome
The system shipped at MOQ 300 in a compact flat-pack format that lowered freight per unit. The brand expanded the module range and reordered with new plush colorways.
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