Economics losses due to fresh produce damage is considered a serious issue in the agriculture industry. Fruits like pears are most susceptible to damage due to their soft and sensitive skin. In this study, rosemary pear 3D finite element (FE) model was established through 3D scanning and reverse engineering methods. Elastic-plastic material properties of pear including modulus of elasticity, density and bio-yield point were measured through mechanical compression test. The FE model was validated with physical bench experimental drop test. A mesh sensitivity analysis was performed in order to ensure optimal balance between results convergence and computational time. A polylactic acid (PLA)-based design structure was proposed in order to serve as a cushioning package for pears. This design has reduced bruising in pear by 65%. Design of experiments (DOE) was performed to investigate the influence of design process parameters in both responses bruising volume and structure internal energy. Response surface methodology results have revealed that circular thickness of structure is responsible for bruising volume. Thinner circular rings would result in minimized localized inner fruit stress. A moderate structural thickness is recommended to be adopted as thicker structures would result in higher internal energy which will be transferred to the fruit as bruising. The proposed design can be extended to be used as a multi cell packaging to accommodate multiple fruits in the same package ensuring the protection for each pear individually. The design can be recyclable, reused, and remanufactured as it is made from PLA. Design practical implications and supply chain insights were addressed along with future research directions. Fresh produce logistics and operations should consider the adoption of such packaging in order to minimize economic losses and extend shelf-life of fruits.
