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How about a booster which is transperant? It will still be packed randomly but instead of the usual cardboard used to make the boosters, Wizkids only have to use the clear plastic!
Printing on the INSIDE of the booster boxes would TRIPLE the cost of each box for wizkids;
1)Print terrain side (the inside MUST be done first because of the glazing on the outside)
2)Allow the box blanks to rest (cool) for 2-3 hours.
3)Reset print system (3-4 hour job due to the glazing)
4)Re-price the booster's to $11.99.
The cost to do the inside of the boxes is higher because as stated it requires retooling the box productiion line or building another line and hiring more people, though this could be helpful in economic terms, for the business and cost to players it could and most likely would result in a higher cost of product. An easy solution would be for them not to produce the terrain pieces out o boxes but to make and sell a more durable type of terrain other than the PDF files available online.
To do this I would suggest making sets consisting of 6 terrain pieces. 2 pieces of each type in most but speacialized sets like an all blocking set for "City" missions, or a :River" set using the water channel terrain designed for being run together as a rive. This will also allow for the future addition of new terrain to be easily incorparated into the game. Terrain like bridges of the water to allow for "Clear" teerain for vehicles that treat water a seither blocking or hindering terrain to treat it a clear when they cross at these points.
These terrain pieces could be made out of composite and still conform to the "official" terrain templates, just be made thin and durable for use.
How about this.......Have some kind of Bubble Wrap inside? and more Qualitie control, no more mechs with 2 left arms, no more stuff thats broken on 90% of the unit type in the box :)