Packaging Designs & Engineering Services

Who We Are

El-Hage Design & Engineering delivers expert packaging design and engineering solutions for manufacturers and businesses nationwide. We specialize in custom expendable and reusable packaging systems, leveraging high-performance wood, foam, plastic, metal, and corrugated materials to build the perfect solution for your specific application.

Our flexible, à la carte services grant your business on-demand access to elite engineering support—without the overhead of a full-time internal resource. We analyze the unique constraints of your project to deliver optimized, tailored packaging solutions across a diverse range of industries:

  • Industrial & Automotive

  • Aerospace & Electronics

  • Healthcare & Pharmaceuticals

  • Agriculture & Horticulture

  • Chemical, Retail, & E-commerce

How It Works

1. DISCOVER

  • Project Assessment: We review your project requirements, project scope, and objectives to align on the services needed.

  • Scope of Work (SOW): We define and document a clear, comprehensive Scope of Work to establish the project boundaries and deliverables.

  • Preliminary Budgeting: Based on the approved SOW, we generate an accurate ballpark quote to ensure financial alignment from day one.

2. DESIGN

  • Conceptual Modeling: We develop a preliminary 3D CAD model to visualize your custom packaging needs.

  • Collaborative Review: We review the concept together, ensuring perfect alignment on the design direction, dimensions, and operational requirements.

  • Advanced Assembly Engineering: We build a fully integrated, linked assembly model embedded with precise material properties (such as wood, foam, plastic, metal, etc.) and execute per SOW.

3. ENGINEER

  • Comprehensive Deliverables: We finalize all technical documentation, 3D models, engineering drawings, and performance analyses.

  • Cost Finalization: We provide an updated, precise final quote based on actual logged engineering hours and finalized project scopes.

  • Validation & Sign-Off: We conduct a final peer review and consultation on the product to guarantee total satisfaction and secure formal project sign-off.

4. MANUFACTURE (IF APPLICABLE)

  • Strategic Manufacturing Placement: We bridge the gap between design and production by matching your approved blueprints with elite, vetted U.S. manufacturing partners best suited for your material, location and volume requirements.

  • Mfg. Handoff & Production Support: We coordinate the handoff to qualified manufacturing partners for cost estimation, prototype sampling, and production feasibility review. This ensures a smooth transition from EDE to manufacturing, with support available throughout the process as needed.

A LA CARTE DESIGN & ENGINEERING SERVICES

Select only the services you need. Projects can be completed individually or combined into a complete design-to-manufacturing solution.

01 — DESIGN SUPPORT

For existing designs, drawings, and engineering data

  • Consultation & Design Review

  • Metric-to-Imperial Drawing Conversion

  • CAD Modeling/Drafting Support/Freelance

  • Bill of Materials (BOM) Conversion & Equivalency

  • Existing Packaging Design Updates

  • Non-Packaging CAD & Design Support

02 — CONCEPT & ENGINEERING

For new designs or improvements to existing products

  • 3D Packaging Design Concepts

  • New Packaging Design

  • Existing Design Conversion & Upgrades

  • Shipping & Sea Container Layouts

  • R&D / Cushion Analysis

  • General Manufacturing Drawings

  • Design-for-Manufacturing (DFM) Review

03 — MANUFACTURING-READY DESIGN

For approved designs moving into production

  • 3D Manufacturing Models
    .STEP | .IGES | .SLDPRT/.SLDASM

  • 2D Layouts for CNC/ Cutting Dies/Tooling (.DXF)

  • 3D Molds/Manufacturing Jigs

  • Assembly & Instruction Drawings

  • Instruction/Assembly Presentation

  • Outsource Drawings

  • Design Review & Engineering Consultation

04 — U.S. MANUFACTURING SUPPORT

From approved design to U.S. production

  • Full Production Drawing

  • Inspection Drawing

  • On-Site Review/Consultation

  • Estimated Quote

  • Manufacturing Support (3rd Party Partners)

  • UN Testing & Reports (3rd Party Partners)

COMMON PACKAGING MATERIALS

Wood • Foam • Corrugated • Plastics • Metal • Hybrid Packaging

📐 Meet the Founder

Alvaro El-Hage is the founder and principal engineer of El-Hage Design & Engineering. Holding a double Bachelor of Science in Mechanical and Manufacturing Engineering, Alvaro recognized early on a widespread industry need for specialized, elite engineering talent in the industrial packaging and logistics sector.

With a vision to build a comprehensive engineering firm, he spent years mastering every corner of the supply chain—from quality assurance, safety, and production to logistics and finance. He further solidified his technical expertise by earning advanced credentials, including Hazardous Materials (HazMat) and Automotive Packaging certifications, alongside a Lean Six Sigma Black Belt.

Having worked across both small firms and major global corporations, Alvaro brings a hands-on, practical approach to the business. He specializes in creating manufacturing-ready designs that transform complex supply chain challenges into efficient, reliable, and cost-effective solutions.

His goal is simple: deliver high-quality, streamlined engineering support that creates immediate value for clients.

🌱 Beyond the Engineering

Born in Santa Cruz, Bolivia, and raised in Wisconsin, Alvaro’s grounded perspective is rooted in a deep appreciation for hard work, community, and the outdoors. Today, he maintains that balance by golfing, traveling, and spending time in nature with his family. This blend of rigorous technical expertise and real-world perspective shapes everything he does, ensuring every project is handled with curiosity, care, and a commitment to doing things right.

Submit an Inquiry

Please complete the brief form below to initiate a conversation with our consulting team and determine how our expertise can facilitate your organizational objectives.

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