Objective To reveal the damage patterns of mangoes under low-velocity impact, and provide a theoretical basis for harvest and postharvest buffer design to reduce losses.

Method The free-fall test was conducted with a factorial design using Vietnamese green mangoes as the objects. The effects of drop height (10, 60, 160, 360, 560 and 760 mm), polyurethane foam thickness (0, 5 and 10 mm), and impact location (flattened and convex ventral part of the mango fruit) on peak impact force, coefficient of restitution, and bruise area were systematically analyzed. Statistical analysis was employed to reveal the influence patterns of these factors and the relationships between parameters.

Result Drop height was the most significant factor affecting peak impact force and bruise area, while polyurethane foam thickness had the most significant impact on the coefficient of restitution. Bruise area showed a significant positive correlation with peak impact force (r=0.919, P<0.01) and a significant negative correlation with the coefficient of restitution (r=−0.393, P<0.01). The critical damage height was lower at the point of the maximum curvature radius on the ventral part of the mango. The addition of 10 mm polyurethane foam increased the critical height by 3.6 to 5.3 times and raised the maximum damage force threshold for premium grade fruits (bruise area < 100 mm²) by 2.11 times.

Conclusion Impact damage is collectively determined by drop height, buffer protection and impact location. Peak impact force and coefficient of restitution can serve as effective indicators for assessing mango damage risk. Increasing buffer materials is the core strategy for reducing postharvest damage, with particular attention needed to protect the more sensitive flattened areas.