When we send units out at our company, we use a cardboard holder that keeps the laptop suspended in the middle of the box, then some thick foam pads to protect the middle of the unit. Then we stufff it with packing peanuts and double box it. For sending from home, a good strategy is to firmly encase the computer in bubble wrap and then use packing peanuts to keep it immobile in the middle of the box. Always use a box with enough room to pad all the way around, and make sure the computer cannot move or it will slide back and forth during shipping. If you can imagine dropping the box from standing height and think that the laptop would be safe, that's a good amount of padding to shoot for. Another tip: if you're including your ac adapter and battery with the laptop, don't stack them against the top case! If something puts pressure on the box and knocks the adapter or battery into the cover of your LCD screen it may break.
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