This article presents the development of an optimization of the package for a certain air purifier. The new design was more environmentally friendly, cheaper to produce, saves storage space and simplifies the repacking processes. The concept was generated in the concept generation phase, and selected among other concepts with the help of Pugh Matrix. After an iterative development process of cushioning design, drop simulation and drop tests, the proposed concept was verified by drop simulations in ANSYS, drop tests following the ISTA 3A standard, and a brief Life Cycle Assessment. Future work was also proposed based on the findings in the project. The theoretical background of the design, the various methods which were used in the development process and the development process itself were presented and discussed in this article. A method of rapid cushioning development was also concluded. The method was suitable for developing a cushioning system made of pre-compressed corrugated paper board based on an existing cushioning system. The method was designed to achieve a rapid iterative development for a new cushioning design with pre-compressed corrugated paper board based on an existing cushioning design.