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

22/09/25 - 22/1/25 [ Week 1 - Week 14 ]

Nicco Chew Jin Xun (0366563)

Packaging & Merchandising Design | Bachelor of Design (Hons) In Creative Media | Taylor's University

Tutor: Mr. Shamsul

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Table of contents

1. Instructions

2. Lectures

2. Exercises 2 / Process work

3. Feedback

4. Reflection

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Instructions

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Lectures

Introduction to Packaging Design

- Packaging is a critical part of our daily life. It impacts the way we live in this global society.

- As the way we live, work & play changes, packaging has to meet the demands of changing consumption, locations and occasions.

- Packaging is the container / wrapping that holds a product and protects it. 

- Packaging design is the process of making the package look attractive & appealing to the consumer, while also considering factors such as the target audience, brand identity & practical considerations like ease of use & sustainability. 

- By creating an effective package design, brands can make their product stand out & connect with consumers on an emotional level.

The evolution of Packaging

Ancient Times (Before Modern Civilizations)

- Early humans used natural materials like leaves, bark, coconut shells, bamboo & animal skins to wrap / carry food & items.
- Ancient Egyptians & Chinese used clay pots to store oils, grains & spices.

Early Civilizations ( Mesopotamia, Egypt, Rome )

- Glass bottles & clay amphorae were introduced for storing olive oil, wine & medicine.

- Romans started labeling their containers using clay seals which kind of like early branding!

Industrial Revolution ( 1700s - 1800s )

20th Century ( 1900s - 2000s )

21st Century - Era of Sustainability & Digital

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Exercises 2 

Designing Custom Boxes for Non-Boxed Items

Timeframe: [ Week 3 - Week 5 ]

For this project, we are required to design custom box packaging for items that do not come in traditional box packaging. The main objective of this exercise is to help us develop our skills in creating packaging solutions that are functional, creative, and visually appealing, while also enhancing the overall presentation of the product.

Through this assignment, we are expected to demonstrate our ability to think critically about packaging structure and how design decisions can improve both functionality and user experience.

Task Description

Item Selection

For this project, we have to choose a non-boxed item from our daily surroundings. The selected item should be relatively small in size, measuring between 15cm and 20cm, and should not already come in conventional box packaging. This allows us to explore how custom packaging can add value to everyday objects.

Justification

We are required to provide a brief justification for our selected item. This includes explaining why custom box packaging is suitable and how it can enhance the item’s presentation, protection, and functionality.

Box Design

Box Structure

For the box design, we have to create detailed diagrams and sketches that clearly show the box structure. This includes accurate dimensions, flap designs, and closure mechanisms. The proposed box must be functional and secure, ensuring that the item is well-supported by the packaging.

Process Work

For this project, I chose socks as the item for which I designed a custom box. My main idea was to create a box that provides sufficient space for storing socks in an organised and practical way.

Socks are commonly sold without proper packaging or are easily misplaced after use. By designing a custom box, the packaging can function not only as protection but also as a storage solution, allowing users to neatly organise and keep their socks in one place. This enhances both the functionality and usability of the product while improving its overall presentation.

Fig. 1 - Socks as the item

After confirming socks as the selected item, I moved on to the research stage by exploring a wide range of references on Pinterest. I looked at different types of box packaging to understand how they are structured and how they function.

During this process, I carefully observed the common features shared across various box designs, such as proportions, opening methods, flap arrangements, and closure mechanisms. This research helped me identify practical and effective design elements that could be adapted for my own sock box packaging.

Fig. 2 - References

I created several rough sketches to explore different box forms, opening methods, and internal space arrangements that could effectively store socks.

Fig. 3 - Sketches

For my final box, I used a laser cutting machine to ensure precision and clean cuts. After finalising my design, I created the dieline digitally, making sure all measurements, flaps, and fold lines were accurate.

Once the dieline was completed, I submitted it directly to the laser cutting machine to produce the box. This method allowed me to achieve a more professional and accurate result compared to manual cutting, ensuring that the final box structure was functional and well-constructed.

Fig. - Final Custom Box

Fig. - Final Dieline (JPEG)

Fig. - Final Dieline (PDF)