This might give you some ideas:
How to shadow a toolbox without tracing or cutting part 2
https://www.youtube.com/watch?v=C_csElQXiFg
Ex military guy? I spent a lot of hrs, days shadowing tool boxes in the USAF. Even did my roll around box at home which was grest for knowing what tools I lost. I finally settled on my new system. Pegboard hangers over the bench, same type tools in each drawer of the roll around, a catch all pile on the shop table between jobs and blame the kids, wife when I can't find a tool.
Over the years I have received a few racks packed in expanding foam from guys who had a machine at their workplace. Cans of that stuff are pricey, gotta do it in halves and cure time, i use USPS free boxes ant it is a vertical pack. I have good luck with plastic foam peanuts. People hate them but they do the job. Bigger boxes would def help. Raises costs for the box and packing. What will the market bear?
I have unboxed racks in too small boxes with 3 sheets of wadded up newspaper for packing arrive with not a scratch. Go figure.