Packaging and Merchandising Design Exercise 2

 Packaging and Merchandising Design

14/04/2026 – 24/05/2026 (Week 1 – Week 6)

WangJiheng / 0378904

Bachelor of Design (Hons) in Creative Media Advanced Interactive Design – Exercise

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TABLE OF CONTENTS

Lectures

Instructions

Exercise2

Feedback

Reflections

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Lectures

In this lecture, we learned about structural packaging design and paper folding engineering.

The lecturer explained that a money packet is not only a flat graphic object, but also a three-dimensional packaging structure that creates user experience through movement, folding, and interaction.

One important concept introduced was the White Model Philosophy. By removing graphics and colours, we can focus more on structure, folds, shadows, and construction quality.

We also learned about die-lines, mountain folds, valley folds, locking systems, and paper grain direction. These structural details affect how the packet opens, closes, and maintains its form.

Another key point was how different paper weights create different structural behaviours. Thinner paper is easier to fold, while thicker paper creates stronger structure but requires cleaner scoring and more accurate folding.

The lecturer also showed different money packet examples from banks and explained how packaging structure can influence the emotional experience of giving and receiving money packets.

Figure 1. Original Money Packet Structure

Figure 1-2. Interior Folding Construction

Figure 1-3. Prototype Opening Mechanism

Figure 1-4. Final Folded Prototype

During class, I deconstructed an existing money packet and recreated its structure using white paper.

I experimented with folding, curved flaps, and a simple locking mechanism to understand how paper tension helps keep the packet closed.

Through this process, I realised that even small cutting inaccuracies can affect the stability and appearance of the final structure. I also learned that thicker paper creates a cleaner and more premium form, but is more difficult to fold accurately.

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Instructions

    

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Exercise 2

RESEARCH & CASE STUDY

Case Study 1 – Decorative Asymmetrical Envelope Structure

Figure 2-1. Envelope Structural Template

This case study explores a decorative envelope structure with an asymmetrical folding system and a curved ornamental flap.

I selected this example because the structure combines both functional folding and visual form. Unlike a traditional rectangular money packet, this design creates a more sculptural appearance through its curved top edges and angled side folds.

The die-line shows how a flat two-dimensional sheet can transform into a three-dimensional container through carefully planned fold lines. The folding sequence also creates a layered opening experience, which makes the interaction feel more engaging.

Another interesting feature is the asymmetrical closure system. The side panels fold inward while the top flap remains visually dominant, creating balance between structure and aesthetics.

This example helped me understand how envelope structures can communicate elegance and emotional value even before graphics or colour are added.

Structural Observation

• Uses multiple fold directions to create volume  

• Decorative curved flap creates stronger visual identity  

• Side folds help reinforce structural stability  

• The opening experience feels layered and interactive

Case Study 2 – Experimental Multi-Flap Folding Structures

Figure 3-1 Experimental Multi-Flap Folding Templates

This case study explores several experimental folding structures created from a single sheet of paper.

Unlike conventional money packet designs, these templates use multiple flap systems and geometric folding sequences to create different forms and opening experiences.

I selected this example because it demonstrates how structural variation alone can completely change the visual identity and interaction of a paper container.

One interesting aspect is the use of symmetrical and radial folding systems. Some structures create soft organic forms, while others create geometric box-like shapes. This shows how fold direction and flap arrangement affect both appearance and functionality.

The die-line layouts also reveal how different folding logics can transform a flat surface into three-dimensional structures without relying heavily on graphics or decoration.

This research helped me understand how paper engineering can create playful, interactive, and sculptural packaging experiences through simple folding techniques.

Structural Observation

• Uses multiple flap systems to create volume and enclosure  

• Different geometric layouts create different opening experiences  

• Fold sequence affects structural stability and interaction  

• Organic curved forms create softer visual language  

• Box-like structures provide stronger containment and rigidity

Case Study 3 – Interlocking Envelope Structure

Fig 4-1: Interlocking Envelope by Andrew Zo

This case study examines the Interlocking Envelope designed by Andrew Zo, a structure that uses no glue or tape for closure, relying entirely on the geometry of the die-line to hold its form.

The most striking feature of this design is its dramatic diagonal fold lines, which create a sculptural, angular appearance that moves far beyond the standard rectangular envelope. The asymmetrical flaps interlock with each other through precise angular cuts, creating a secure closure without any adhesive.

I selected this example because it directly demonstrates the core principle of our exercise — that structural logic alone can replace glue. The die-line shows how a single flat sheet transforms into a three-dimensional container through carefully calculated fold angles.

The opening experience is also notable. As shown in the sequence photographs, the packet opens in a sliding, wing-like motion that feels intentional and elegant. This kinetic quality adds emotional value to the act of giving and receiving.

Structural Observation

• Uses interlocking diagonal flaps with no adhesive required
• Dramatic fold angles create visual interest without surface graphics
• Single sheet construction reduces material waste
• The opening motion is smooth and reveals contents gradually
• Angular geometry creates a strong, distinctive silhouette

Ideation

After completing the research, I began developing my own money packet structures based on the idea of “white-out”. Since the final design could not rely on printed graphics, I focused on the shape of the flap, the folding sequence, and the locking mechanism.

My first direction was based on a glueless interlocking packet. I wanted the structure to remain close to the function of a traditional money packet, but with a more sculptural opening and closing experience. I explored how the top flap could lock into a slit without using glue or tape.

My second direction focused on making a cleaner envelope-style packet. Instead of using another interlocking system like the first design, I explored a glued pocket body with a large rounded arc flap. This allowed the second design to feel softer and more minimal while still showing a different structural approach.

Fig 5-1. Initial Ideation Sketches

During the ideation stage, I learned that even small changes to the shape of a flap can affect the whole personality of the packet. A straight rectangular flap feels very formal and flat, while a curved flap creates a softer and more crafted appearance. I also realised that the locking area must be large enough to be functional, but not too large that it becomes visually distracting.

Prototype Development 1 – Curved Brace Interlock Packet

 

The first prototype was developed from a basic rectangular money packet structure. The main structure includes a front panel, a back flap, two side locking panels, and a top flap with an interlocking tab. The aim was to create a secure money packet without glue.

 

In the first version, the overall form was too rectangular and the top flap looked too plain. The locking tab was also very small and the side panels did not provide enough support. After receiving feedback, I modified the design by changing the top flap into a curved brace-like shape, extending the side panels, and redesigning the tab into a half-circle form.

Fig 6-1. First Prototype of Glueless Money Packet

Fig 6-2. Lecturer Feedback on Flap Shape and Locking Detail

The lecturer pointed out that the original top flap was too box-like. To improve this, the upper edge was redesigned into a more organic curved form, similar to a brace shape. This helped reduce the rigid appearance and made the packet look more designed even though it remained completely white.

 

The bottom locking area was also changed from a straight tab into a half-circle tab. This made the interaction feel smoother and more intentional. The side panels were extended so that the internal structure could hold the banknote more securely.

Fig 6-3. Final Die-line for Curved Brace Interlock Packet

Technical Features

·       Main body size is designed to fit a standard banknote comfortably

·       Curved upper flap creates a softer silhouette

·       Half-circle tab locks into the slit without glue

·       Extended side panels improve structural stability

·      Opening sequence creates a multi-stage reveal

Fig 6-4. Final Closed View of Curved Brace Interlock Packet

Fig 6-5. Open View Showing Internal Fold and Banknote Space

The final version successfully solved the main issue of the first prototype. The packet still maintains a simple white appearance, but the curved flap and half-circle locking system give it a more refined and intentional structure. The opening process also feels more careful because the user needs to release the tab before unfolding the packet.

Prototype Development 2 – Arc Pocket

 

For the second design, I wanted to avoid using a common origami-style money packet because it felt too familiar and predictable. After testing a more complicated lifting structure, I simplified the final version into an arc pocket structure that was easier to construct accurately while still looking different from the first packet.

 

This packet uses a glued outer pocket with a clean rounded arc flap. The body is assembled using two side glue wings, while the final closure uses the curved flap and the front slot. Compared with the first packet, this design is more like a soft envelope structure, focusing on a simple rounded form and a clean open-and-close experience.

Fi 7-2. Final Die-line for Arc Pocket

The form of the second packet is simpler and more controlled. The large arc flap creates a softer visual language, while the front pocket gives the packet a secure and practical structure. The curved slot also adds a small interaction because the user needs to release the flap before opening the packet.

 

Technical Features

·       Large rounded arc flap creates a soft envelope-like silhouette

·       Curved slot keeps the packet closed through a tab-and-slot action

·       Side glue wings create a stable pocket body

·       The structure is simple enough to cut and fold accurately by hand

·      Glue is used for body construction, while the opening is controlled by the flap and slot

Fig 7-3. Final Closed View of Arc Pocket

Fig 7-4. Open View of Arc Pocket

This design creates a calmer and more envelope-like experience compared to the first packet. The first design focuses on a glueless interlocking system, while the second design focuses on a glued pocket body with a clean rounded flap. Together, both designs show two different approaches to structural money packet design.

FINAL SUBMISSION

Final High-Fidelity Mockup

Fig 8-1. Final Closed View of Curved Brace Interlock Packet

Fig 8-2. Open View Showing Internal Fold and Banknote Space

Fig 8-3. Final Closed View of Arc Pocket

Fig 8-4. Open View of Arc Pocket

Fig 8-5 Technical Die-line of Curved Interlock Packet

Fig 8-6. Technical Die-line of Arc Pocket

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Feedback

Week 4 Feedback

There was no class in Week 4. During this week, I continued developing the money packet structures independently and focused on testing how the folds, tabs, and slots worked with paper. I also used this time to refine my mockups and prepare questions for the next consultation.

Week 5 Feedback

In Week 5, I received feedback on my first glueless money packet. The main comment was that the original structure looked too rectangular and needed a more interesting silhouette. The top flap was suggested to be changed into a softer curved shape, and the locking tab was adjusted into a semicircular form. The side flaps were also extended to make the structure more secure when folded.

For the second packet, the feedback helped me realise that the structure should not be too complicated. Instead of using a very complex folding mechanism, I simplified the design into an arc pocket structure with a curved top flap, front pocket, and side glue wings. This made the packet easier to construct while still showing a different opening experience from the first design.

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REFLECTION

Experience

In this exercise, I learned how to design a money packet by focusing mainly on structure instead of decoration. Since the project required a white-out approach, I could not rely on colour, graphics, or surface patterns to make the design interesting. This pushed me to think more carefully about folding logic, closure systems, paper tension, and the way the packet moves when it is opened.

My first final design was a curved interlock packet without glue. After receiving feedback, I changed the original rectangular shape into a softer curved silhouette and refined the locking system with a semicircular tab and slot. My second final design was an arc pocket structure with glued side wings. This version was simpler and more practical, but it still created a different opening experience through the large curved flap and front pocket.

Observation

Through the making process, I observed that small changes in measurement can strongly affect how the money packet works. The width of the side flaps, the position of the slot, and the shape of the tab all influenced whether the packet could close securely. I also noticed that curved edges made the white paper structure look softer and less box-like, which helped the form feel more intentional even without printed graphics.

When testing the second packet, I found that a simple structure can sometimes work better than a complicated mechanism. The arc pocket was easier to cut, fold, and assemble, and it still allowed the banknote to be held securely. This helped me understand that structural design should balance creativity with usability.

Findings

From this project, I found that a successful money packet structure needs to consider function, material, and user interaction at the same time. A design may look interesting on the dieline, but it must also be easy to fold, strong enough to hold a banknote, and clear enough for the user to open and close.

I also found that white paper makes construction quality more visible. Every curve, fold line, slot, and shadow becomes part of the final visual outcome. Overall, this exercise helped me understand that packaging design is not only about appearance, but also about how paper moves, locks, supports, and creates an experience for the user.