What Is the ISTA Drop Test and Can You Do It Yourself?
When it comes to e-commerce shipping, nothing undermines a brand’s reputation faster than a broken product. That's why package testing, particularly the ISTA drop test, is such a vital part of the supply chain for any business shipping physical goods. This straightforward yet highly effective test simulates one of the most common real-world shipping hazards: dropping.
In this post, we’ll break down what the ISTA drop test involves, why it matters, which ISTA protocols include it, and whether your brand can perform it in-house—or if you’ll need a certified lab.
What Is the ISTA Drop Test?
The ISTA drop test simulates the shocks and impacts that a package may endure during handling and transit. Think about how many times a box might be dropped: off a conveyor belt, from a shelf, or during manual loading and unloading. This test helps ensure your packaging can handle those incidents without product damage.
During the test, a packaged product is dropped from specified heights and angles to mimic real-world handling scenarios.
Key Goals of the Drop Test:
Assess structural integrity of the packaging
Evaluate internal cushioning or dunnage performance
Ensure product survival after common drops
Predict and reduce damage during transit
How Is the ISTA Drop Test Performed?
While the exact procedure depends on the specific ISTA protocol (like 1A, 3A, or 6-Amazon.com), the general approach is consistent across most tests.
Typical Drop Test Steps:
Preparation: The product is packed as it would be for actual shipment.
Drop Height Determination: Drop height is based on the package’s weight.
For example:
Under 21 lbs (9.5 kg): drop from 30 inches (76 cm)
21–40 lbs: drop from 24 inches (61 cm)
41–60 lbs: drop from 18 inches (46 cm)
Orientation Drops: The package is dropped on different faces, edges, and corners.
Common orientations:
Flat drop (top, bottom, sides)
Edge drop (diagonal edge)
Corner drop (one corner striking surface)
Evaluation: After each drop, the product and packaging are inspected for damage.
ISTA protocols specify the number of drops and orientations. For example, ISTA 1A includes 10 drops, while Amazon’s ISTA 6 requires even more rigorous corner and edge testing.
Which ISTA Test Protocols Include Drop Testing?
Almost all ISTA protocols include some version of drop testing, but here are the most relevant ones for e-commerce and retail brands:
ISTA 1A/1B/1C: Basic integrity tests including multiple drops
ISTA 3A: Small parcel simulation (includes drops and vibration)
ISTA 6-Amazon.com: Amazon’s FFP, SIOC, and PFP tests require detailed drop sequences
ISTA 7D: May include drops for thermal packaging systems
Can You Perform an ISTA Drop Test Yourself?
Short answer: Yes! But with limitations.
If you’re looking to explore packaging weaknesses or run preliminary R&D tests, you can absolutely perform a drop test in-house. Many small to midsize brands create a DIY version of the ISTA drop test using basic equipment and following published ISTA guidelines.
DIY ISTA Drop Test Setup:
Use a flat concrete or hard floor to simulate a standardized drop surface.
Measure drop height precisely using a tape measure or drop rig.
Record the orientation and impact point of each drop.
Inspect and document the results after each drop (internal damage, packaging failure, etc.).
However, if you need to submit official test results to Amazon, Walmart, FedEx, or other partners, you must go through an ISTA-certified lab.
When Should You Use a Certified Lab?
If any of the following apply, you’ll need certified testing:
You're selling on Amazon (FFP/SIOC compliance)
You're working with big-box retailers (Walmart, Target)
You're launching a new product with fragile or high-value contents
You want to minimize damage claims and prove packaging reliability
ISTA maintains a searchable list of certified labs on their website: www.ista.org
Final Thoughts: Drop Testing Is Smart Business
The ISTA drop test is one of the most cost-effective ways to protect your brand from avoidable damage, returns, and bad reviews. While certified lab testing is essential for compliance and large-scale retail, DIY drop testing is a powerful tool for small brands, startups, and anyone prototyping new packaging designs.
At Rogue Fulfillment, we help e-commerce brands reduce damage and improve packaging performance—whether you need advice on box strength, dunnage, or coordinating certified testing with a trusted lab.
Need help preparing your packaging for drop tests or retail compliance?
Contact Rogue Fulfillment for expert guidance, packaging audits, and support that scales with your business.