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)

TABLE OF CONTENT

1. Lectures

2. Instructions

3. Process Work

4. Final Outcome

5. Feedback

6. Reflection

7. Further Reading

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)

2. INSTRUCTIONS

Fig. 2.1. Module Information Booklet (MIB)

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.

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)