Packaging & Merchandising Design: Exercise 2 (Designing Custom Boxes for Non-Boxed Items)

 22/04/2025 – 06/05/2025 (Week 1 – Week 3) 

Valerius Ethan Wirawan / 0372774

Publishing Design / Creative Media / School of Design 

Packaging & Merchandising Design: Exercise 2 (Designing Custom Boxes for Non-Boxed Items)

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TABLE OF CONTENT

1. Lectures

2. Instructions

3. Process Work

4. Final Outcome

5. Reflection

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1. LECTURES

1.1. Lecture 1: Introduction of Packaging (06/10/2025)

1.2. Lecture 2: History of Packaging (W3)

1.1. Lecture 3: Packaging Materials & Type (W4)

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2. INSTRUCTIONS

Fig. 2.1. Module Information Booklet (MIB)

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3. PROCESS WORK

Exercises 2: Designing Customed Box for Non-Boxed Items

Task Brief

For this assignment, select two small items from your surroundings (each 15–20 cm) that do not come in traditional box packaging. Explain briefly why each item would benefit from a custom box in terms of presentation and functionality. Design detailed box diagrams for both items, including measurements, flap designs, and closure mechanisms, making sure your box ideas are both functional and secure. Then, construct physical prototypes of the boxes, using cardboard or a suitable material, and upload your process and results to your e-portfolio.

I began by selecting Muay Thai essentials that are typically sold without boxes to package with my new design. After careful consideration, I chose two hand wraps (one for each hand) and a mouthguard as the featured items for this packaging concept.

Fig. 3.1. Product: Handwraps & Mouth Piece

Next, I initiated the ideation process for the packaging design, exploring creative concepts and functional solutions tailored to the selected Muay Thai products.

Fig. 3.2. Ideation & References

After brainstorming ideas, I translated my concepts into initial sketches. I started by drawing the bottom and upper sections of the box, visualizing the overall structure. Once I had a clear picture of the form, I proceeded to create several sketches exploring different die-cut designs.

Fig. 3.3. Sketches of Packaging's Design & Diecut

The die-cut design was further developed through prototyping. During this process, I continually revised the measurements to ensure accuracy as I constructed the box prototype. One key adjustment was the addition of material thickness, which significantly influenced the final die-cut dimensions. The thickness of the chosen material directly impacted the overall structure and fit of the packaging.

Fig. 3.4. Prototyping Process 

Herewith are the diecut file in PDF format.

Fig. 3.5. Diecut (PDF - 20/10/2025)

Once the prototyping and measurements were finalized, I exported the die-cut design from Adobe Illustrator in the ‘.dxf’ format. This file was then uploaded to the laser cutting machine, which precisely cut the material according to the finalized die-cut layout.

Fig. 3.6. Laser Cut Process

Fig. 3.7. Iteration Process After Lase Cut

Following the initial cutting process, I measured the prototype and made further adjustments to enhance its suitability for the Muay Thai products. This iterative process involved multiple rounds of laser cutting. In total, I went through six cycles of revisions, from the first prototype to the final, perfected die-cut.

Fig. 3.8. Final Laser Cut Diecut Cardboard

This is the final version of the packaging design, perfectly tailored for the unboxed Muay Thai products.

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4. FINAL OUTCOME

Exercises 2: Designing Customed Box for Non-Boxed Items

Fig. 4.1. 'Exercise 2: Designing Customed Box for Non-Boxed Items' Final Outcome (JPEG - 24/10/2026)

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5. REFLECTION

Throughout Exercise 2 of the Packaging & Merchandising Design module, I gained valuable hands-on experience in designing custom box packaging for items that are not traditionally boxed. By working with Muay Thai hand wraps and a mouthguard, I was able to explore how packaging can enhance both protection and presentation for functional sports products. This project challenged me to think beyond aesthetics and focus on structural design, material considerations, and real-world usability. The process of translating ideas from sketches to physical prototypes helped me better understand how packaging design operates as a bridge between concept and practicality.

During the development process, I observed that accuracy in measurements and material thickness played a crucial role in determining the success of the packaging structure. Initial prototypes revealed issues such as improper fit and structural instability, which required continuous refinement. Through multiple iterations, especially during the laser-cutting stage, I learned that even small adjustments could significantly impact the overall functionality of the box. This experience highlighted the importance of prototyping and testing, as digital designs do not always translate perfectly into physical forms without revision.

From this project, I learned that effective packaging design requires a strong balance between form, function, and production feasibility. The repeated iteration process strengthened my problem-solving skills and taught me to be more detail-oriented, particularly when working with die-cuts and physical materials. Most importantly, this exercise helped me view packaging not just as an outer container, but as an integral part of the product experience that adds value, protection, and identity. Overall, this project deepened my understanding of structural packaging design and reinforced the importance of thoughtful design decisions in real-world applications.