In this article, we will look briefly at various options, and examine a new, environmentally friendly version that uses up old plexiglass strips.

SUMMARY

REINFORCED BOX CORNERS	PLEXIGLASS CORNER PROTECTORS
Various styles for padding and structural support: Styrofoam Cardboard Bubble wrap Rubber Plastic Metal	Thin strips of left-over plexiglass (acrylic glass) can be bent using heat to create strong, rigid protective corners for heavy items being shipped.

STYROFOAM CORNERS

These triangular, slotted protectors are made to slide over the corners of a picture frame or other right angle-edged items (such as stacks of plexiglass or wood panels).

These corners provide padding to keep sharp edges from being dinged or chipped during transport. Very sharp corners, like those of glass or aluminum sheeting, can still slice through the foam, however.

One advantage to styrofoam corners is the ease with which they can be altered. When applied to a frame that grows deeper toward the center, a triangle piece can be cut from the top of the corner, to allow for this rise, without sacrificing the integrity of the protection.

For square-angle items that are thicker than frames, foam corners with an open top and coverage on the other three sides are also on the market.

CARDBOARD PROTECTORS

Cardboard corner protectors look similar to styrofoam corners, but are made by folding and securing a strip of cardboard into a triangular shape. They are more suitable for protecting the box corners, since they don't offer any cushioning.

Strips of cardboard can also simply be folded at a 90-degree angle and placed between the corners of the frame and the edge of the box to provide a bit of extra protection. This is advisable even if the item is not overly heavy, to provide a barrier between the delicate frame and the staples used to hold the box together.

OTHER CORNER PROTECTORS

• Bubble wrap corners
• Full-edge cardboard and styrofoam protectors
• Cardboard corners with adjustable depth
• Hard plastic or rubber corner and frame protectors
• Shaped metal corner protectors

Cardboard corners

Plastic corners

Though framers try to cut their glazing to create as little waste as possible, there will inevitably be some remains, often useless pieces not more than an inch or two wide. These pieces generally end up in the discard pile since no one ever orders a picture frame with an opening of 2x10"!

But by bending these otherwise garbage-bound strips 90 degrees, you can create super-strong corner reinforcers for your delicate, heavy frames and materials.

1. Compile your stack of plexiglass strips. 1 and 2 inch strips are handy, but don't forget about the multiple frame orders that could result in boxes 3, 4, or even 6 inches deep.

2. Build yourself a Corner Protector Form. At KeenART Media, we did this by gluing a number of miter-edged wood strips to a sheet of thin plywood. You can see our makeshift Form in the pictures to the right.

3. Get your blowtorch ready. You'll need a very hot flame in order to soften the plexiglass efficiently. You may want to wear heat-protective gloves, and line your table or floor space with a thick, heat-resistant material (ie: not a towel!).

4. Holding one end of the strip, aim the blowtorch at about center and move it up and down along the width of the strip. You'll want to be quite close so it doesn't take too long, but avoid getting so close the plastic begins to drip or bubble.

5. Turn the strip and do the same to the other side. If the torch is hot enough, you shouldn't need to spend more than 10 seconds or so on each side.

6. When you can see the strip beginning to droop a little in the center, it is likely soft enough to bend. Place the strip in your Corner Protector Form to hold its shape until it cools down and hardens again.

7. Repeat these steps for the rest of your strips. You can make your form with as many spaces as you need, but once it's full, be sure to leave the bent strips until they have hardened back to their original stiffness.

These handmade corner protectors can now be used as extra reinforcement for those big, heavy shipments. They will not pad your product, so you will still want to cover the corners with foam or bubble wrap, but you'll see fewer broken box edges with these handy accessories in place!

Plexiglass corner protectors are a great way to lessen your carbon footprint. You'll be using up scrap acrylic instead of extra cardboard or pre-purchased plastic protectors, and you can prepare a wide variety of lengths and depths so you always have exactly the size you need.

This homemade wood form holds the strips as they cool

A blowtorch can be used to soften the strip at the center

To learn more about custom shipping materials, see our article on Making Custom Shipping Boxes.

If you have questions about any of our services or products, don't hesitate to contact us. Our knowledgeable staff is always happy to assist with answers, advice, or suggestions.

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