AbstractAs an extension of the classical damage boundary curve in the case of product dropping shock, the concept of a dropping damage boundary curve for linear and non‐linear packaging system to evaluate the dropping damage of product is developed in this paper. The dropping damage boundary curves are given for linear and hyperbolic tangent packaging systems with different damping. For a linear packaging system the dropping damage of a product is determined only by the natural frequency of the corresponding packaging system without damping and the dropping shock velocity of package except the system damping, and they compose the basic evaluation quantities of product dropping damage. For a non‐linear hyperbolic tangent packaging system, the system parameter and the dimensionless dropping shock velocity are two basic quantities in the evaluation of product dropping damage. It should be emphasized that the dimensionless dropping shock velocity is related not only to the dropping height of package box but also to the system parameter integration. This is the important feature differentiating a non‐linear packaging system from a linear one. The influence of system damping on the dropping damage boundary curves is also discussed. This concept and the results have important value in the design of cushioning packaging. Copyright © 2002 John Wiley & Sons, Ltd.