Abstract: An actuator system for fabricating a cavity within thermoplastic material includes a plurality of actuators arranged in an array. When dimensions of an item are determined, the actuator system may be programmed with data regarding such dimensions to fabricate a cavity for the item. A subset of the actuators, and distances by which each of the actuators is to be extended, may be selected based on dimensions of the item, in order to fabricate a cavity within the thermoplastic material that may accommodate the item therein. Additionally, the actuators and the distances may be selected based on intrinsic or extrinsic data regarding the item, and a cavity fabricated within the thermoplastic material may include one or more buffer zones or protective regions that are specifically formed with respect to aspects of the item.

Abstract: A padded mailer includes elongated air cells that provide stiffness, especially in the transverse direction. The increased stiffness helps prevent the mailer from flipping over during conveying, which would put a label on the underside of the mailer.

Abstract: A padded mailer includes ribs that provide stiffness, especially in the transverse direction. The increased stiffness helps prevent the mailer from flipping over during conveying, which would put a label on the underside of the mailer.

Abstract: A package preparation system includes a material conveyable along a longitudinal direction and including two folded layers of polymeric film joined at a fold. The fold extends longitudinally and defines a first side of the material opposite an open second side. A first welding device forms partition welds located between the two folded layers and extending from the fold to a terminus inward of the open side. A second welding device forms first and second seal welds that extend from the fold to the open side and are spaced from each other by a length extending longitudinally and traversing a plurality of the partition welds. The system includes a device comprising a nozzle insertable in the open side, and clamps that traverse the length and temporarily seal the open side around the nozzle while the nozzle inflates interior channels defined between the plurality of partition welds.

Abstract: An actuator system for fabricating a cavity within thermoplastic material includes a plurality of actuators arranged in an array. When dimensions of an item are determined, the actuator system may be programmed with data regarding such dimensions to fabricate a cavity for the item. A subset of the actuators, and distances by which each of the actuators is to be extended, may be selected based on dimensions of the item, in order to fabricate a cavity within the thermoplastic material that may accommodate the item therein. Additionally, the actuators and the distances may be selected based on intrinsic or extrinsic data regarding the item, and a cavity fabricated within the thermoplastic material may include one or more buffer zones or protective regions that are specifically formed with respect to aspects of the item.