15 / 05 / 2025 — 13 / 06 / 2025 (Week 05 — Week 08)
Kim Seoyoon / 0357755
Project 01 / Designing Custom Boxes for Non-box Items
MER 60104 / Packaging and Merchandising Design / Bachelor of Design (Hons) in Creative Media / Taylor's University
Project 01 / Designing Custom Boxes for Non-box ItemsTABLE OF CONTENTS
INSTRUCTIONS
LECTURES
EXERCISES
FEEDBACK
REFLECTION
INSTRUCTION
Module Information Booklet
PROJECT 01– Designing Custom Boxes for Non-box Items (20%)
Timeframe: Week 05 – Week 07 (Deadline Week 08)
Designing Custom Boxes for Non-Boxed Items:
The objective of this assignment is to develop your skills in creating custom packaging solutions for items that do not come in traditional box packaging. By the end of this assignment, you should be able to demonstrate your ability to design functional, creative, and visually appealing boxes that enhance the packaging and presentation of non-boxed items.
Task Description
Item Selection: Choose two non-boxed items from your daily surroundings. The size of the item is between 15cm to 20cm. These items should not come in traditional box packaging but should be relatively small in size (e.g., a mug, a book, a pair of sunglasses, a candle, etc.).
Justification: Provide a brief justification for your selection of these items, explaining why custom box packaging would enhance their presentation and functionality.
The objective of this assignment is to develop your skills in creating custom packaging solutions for items that do not come in traditional box packaging. By the end of this assignment, you should be able to demonstrate your ability to design functional, creative, and visually appealing boxes that enhance the packaging and presentation of non-boxed items.
Task Description
Item Selection: Choose two non-boxed items from your daily surroundings. The size of the item is between 15cm to 20cm. These items should not come in traditional box packaging but should be relatively small in size (e.g., a mug, a book, a pair of sunglasses, a candle, etc.).
Justification: Provide a brief justification for your selection of these items, explaining why custom box packaging would enhance their presentation and functionality.
Box Design
Box Structure: Create detailed diagrams or sketches of the box structure for each item, including dimensions, flap designs, and closure mechanisms. Ensure that the proposed box is functional and secure.
Prototype: Create physical prototypes of the custom boxes for both selected items. You can use cardboard or other suitable materials to bring your designs to life.
LECTURES
Week 03– Introduction to Packaging Design
Fig 1.1 Week 3 Lecture Slides, Week 03
Week 04– Box types and styles
Fig 1.2 Week 4 Lecture Slides, Week 04
Week 05– Packaging and Branding
Fig 1.3 Week 5 Lecture Slides, Week 05
PROJECT 01– Box Making
Week 04 – Non-box Item Preparation & SketchingIn the previous weeks, Mr Shamsul instructed us to gather 2 non-box items for the first project of the module. Here are the items that I prepared:
Fig 2.1 Non-box item 1 (Wooden Clips), Week 04
Fig 2.2 Non-box item 2 (Face Mask), Week 04
Justification
Item 1: Wooden Clip
I chose wooden clips because once they are opened from a single-use plastic packaging, these clips are easy to lose unless stored in one place.
Item 2: Face Mask
Sometimes face masks are sold individually, so I thought that placing different types of face masks in one packaging would be great for consumers.
Research/ reference images
(a) References & inspirations for wooden clip packaging design
Fig 2.3 References designs & inspirations, Week 04
As the wooden clips are often used for crafting, I wanted to design my packaging that is suitable for children. Therefore, I looked for references that are practical in presenting the product with fun designs.
(b) References & inspirations for face mask packaging design
Fig 2.4 Inspiration& reference packaging designs, Week 04
For face mask, I wanted to try a file/ book type of design that can categorize different types of face masks.
Sketches
After Mr Shamsul's approval of the objects, we were instructed to create a few sketches on the initial packaging designs that we would like to design for the chosen items. Below is my sketch:
1. Sketches for wooden clips
For wooden clips, I proposed 3 different types of box designs.
Fig 2.5 Sketch for Wooden Clips, Week 04
a) Drawer-type box design
The first design is a drawer-type box packaging that holds wooden clips with a peeking window on the top of the box.
b) Triangular clip dispenser
The second design has a triangular shape that opens horizontally which revealing rows of wooden clips clipped on the paper slope.
c) Crocodile tooth
The last design is targeted at children and is designed based on a crocodile's face. The open mouth of the crocodile acts as a window for users to look through the number of clips left in the box.
2. Sketches for face masks
I proposed 2 ideas for face mask packaging design:
Fig 2.6 Sketch for Face Mask, Week 04
a) Book-type packaging
The first design has an outer cover that holds the book pages in one place. The overall book design is secured with a string lock, and its inner pages are able to hold a face mask on each page.
b) Carton type packaging with categorizing dividers
The second design has a divider on the inside of the box that allows the user to categorize different types of face masks.
Week 05 – Prototyping
In week 5, Mr Shamsul looked through the sketches we had prepared from the previous week and discussed which idea would be great for proceeding with prototyping for project 1. He suggested that idea 3 and idea 1 look good respectively for wooden clips and face masks.
During lecture hours, he also gave us a tutorial on creating die-cutting lines on Adobe Illustrator:
Fig 2.5 Die cutting lines tutorial by Mr Shamsul, Week 05
Here are some of the important notes from the tutorial on creating die-cutting lines:
- Use mm measurements for the laser cut diagram on Adobe Illustrator.
- No fill colour needed for the diagram.
- Line Point size: 0.5pt (must keep this size)
- Avoid the laser cutting machine to think there are two lines, use direct selection to delete one side of the line and make sure there's only one line left on the diagram.
- Use the align panel to align the objects
- Use another colour on the scoring line.
- Dont forget the glue part
- Do NOT group your objects
- Save your file to > export as >DXF file > version 2018
- Bring your file on a thumb drive (USB)
Week 06 – Prototyping
In week 6, I created physical prototype models for my packaging design ideas chosen previously in week 5.
1. Chosen packaging ideas:
Fig 3.1 Chosen Ideas for packaging design, Week 05
2. Dieline layout designs
(a) Prototype 1 for Wooden Clips
Fig 3.3 Dieline and cutout for prototype 1, Week 06
(b) Prototype 2 for Face Mask
For prototype 2, I began by creating a dieline layout for the inner pages of the packaging. I planned this inner page part of the packaging to be created in multiple sheets so that I can stick them together into a book form.
Fig 3.4 Dieline and cutout for prototype 2, Week 06
Fig 3.5 Prototyping, Week 06
3. Consultation & Feedback
Fig 3.6 Face Mask Prototype, Week 06
Fig 3.7 Reference dieline, Week 06
After showing Mr Shamsul my prototypes, he commented that I should make the space in between the inner pages for face mask packaging a little larger so that u can see what's inside better. Therefore, I changed my dieline from a singular fold to an accordion fold like the reference from Fig 3.7.
Fig 3.8 Wooden Clips Prototype, Week 06
For the design of my wooden clips packaging, he suggested that I should try separating the parts of the cover and the box so that the whole structure does not have to require a dust flap that blocks the window (crocodile mouth).
Week 07 – Prototyping & Laser Cutting
1. Laser Cutting
In week 7, Mr Shamsul taught us how to use the laser cutting machine. He gave us a demo on how to set the power & speed settings of the laser and how it works.
Fig 4.1 Trying out laser cutting for the first time, Week 07
I also tried my very first attempt on laser cutting. Unfortunately, there was some error with the machine that accidently cut one of my box's flap. However, it was a good experience for me to get used to the machine and also discover things to improve in my dieline layouts.
Fig 4.2 Attempt #1, Week 07
Above is my first try at laser cutting for my wooden clips packaging design. I initially placed the crocodile's eyes at the side, but when I laser cut, the back of the cover did not have enough surface support to maintain the rectangular shape. So I decided to change the eye positions to the centre.
2. Making Adjustments
Fig 4.3 Dieline adjustment before (left) & after (right), Week 07
From the first attempt, I found out that the inner flaps are not supposed to be in the same width as the outer flaps, and it was also the main reason why the folding felt too tight in the first attempt. Therefore, I made several adjustments to the dieline layout.
Week 08 – Laser Cutting & Final Outcome
1. Finalized Dieline
Below are my finalized dieline layouts for my packaging designs.
Fig 5.1 Wooden Clips Dieline, Week 8
Fig 5.2 Face Mask Dieline (Pages), Week 8
2. Laser Cutting
Here are the progress attempts on the outer cover for my wooden clip packaging:
Fig 5.3 Attempt 2, Week 8
Fig 5.4 All of my laser cut attempts #1-7 (left to right), Week 8
Thankfully, I did not face any problems with the face mask laser cutting, but I had several minor issues with the outer cover for my wooden clip packaging regarding to the measurements. After some trial and errors, I gradually came to a suitable measurement that work great both as a cover and also to hold the box inside just right.
3. Assembling
For face mask packaging, I used double sided tape to attach each part together. Since I used manila card to print the inner pages, I did not make any engraving marks on the paper and hand-folded the pages manually.
Fig 5.5 Face Mask pages assembling, Week 8
I also used corrugated box as hardcover for my face mask packaging to hold the file more sturdily.
Fig 5.6 Face Mask Cover, Week 8
Additionally, I added a velcro lock to the outer cover of the face mask packaging so that the masks inside don't fall out of the file.
Fig 5.7 Added velcro lock, Week 8
4. Final Outcome
Below are photographs of my final pacakaging design for this project.
Fig 6.1 Final Packaging Design for Wooden Clips, Week 08
Fig 6.2 Final Packaging Design for Face Mask, Week 08FEEDBACK
Week 04
- Mr Shamsul reminded me that I was supposed to gather two items and not one, so I went on and added one more item, which was a facial skincare mask.
- He also advised us to begin the project by sketching out several packaging design ideas for the chosen items.
Week 05
- Mr Shamsul commented that I can proceed with idea 3 for wooden clips and idea 1 for face masks.
- For prototyping, he advised that I should try both types of locking systems for ribbon and string locks.
REFLECTION
Overall, this project taught me various insights about packaging. I learned how to create dielines for the first time and created packaging tailored to chosen items. It was enjoyable to explore suitable packaging designs that match the purpose of the product usage. Experimenting with the right size measurement for the dieline during the laser cutting process also helped me a lot in getting used to the machine. At the beginning of this project, I was completely new to the laser cutting machine, but with trial and error, I soon gained more knowledge and was able to operate the machine better. I also learned that getting the right measurement is crucial in packaging design, as even the slightest millimetres can change the closure of the box. It helped me to pay attention more to these details and be more gentle with my craftsmanship. Although I had some ups and downs during the procedure of laser cutting, completing this project was very meaningful to me in trying out new things.
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