Structural Packaging Design Your Own Boxes And 3d Forms

[Skye Severy]

Unlikeother packaging titles, which simply provide templates to copy, this book enables designers of all packaging types to create 3-D packaging forms that are specific to their needs rather than based on an existing design.

Structural Packaging gives the reader an understanding of the underlying principles of packaging construction and the technical knowledge and confidence to develop a greater number of their own unusual and innovative designs than any comparable book.

It teaches a simple 'net' construction system - a one-piece 2-D configuration of card seen when a 3-D package is opened out and flattened - which enables the designer to create a huge number of very strong 3-D packaging forms that are both practical and imaginative. Each chapter concludes with photographs and net drawings of 6-10 creative examples of packaging designs made using the principles outlined in the preceding chapter.

Straight tuck folding cartons have top and bottom flaps located on the same side. This design saves space and reduces storage costs, making it economical for manufacturers and retailers. This carton style is versatile and suitable for many different types of products, including retail goods, pharmaceuticals, and personal care items. They offer ease of assembly and a clean, professional appearance on store shelves, enhancing product visibility and consumer appeal.

Reverse tuck folding cartons feature top and bottom flaps on opposite sides, offering a secure closure and easy opening experience for consumers. This carton box type provides a sleek and polished look that enhances product presentation. Many brands in the cosmetics, food and beverage, and health and wellness industries use this style of carton. Reverse tuck cartons facilitate efficient packing and unpacking processes.

Auto bottom paperboard folding cartons are designed to automatically erect when opened, minimizing assembly time and labor costs in packaging operations. They are ideal for products that require quick and efficient packaging, such as food items, cosmetics, and pharmaceuticals. The auto-lock bottom feature ensures a secure base, enhancing product stability during transportation and on store shelves. This type of carton offers convenience and reliability, making it a preferred choice for high-volume production environments.

Lock bottom paperboard folding cartons are specifically engineered for heavier items that require extra strength and durability during packaging and transport. They feature a secure locking mechanism at the bottom, which provides enhanced structural integrity and prevents the box from collapsing under the weight of its contents. Electronics, household appliances, and automotive parts brands often choose lock bottom cartons for their packaging.

Two-piece paperboard folding cartons consist of separate top and bottom pieces that fit together to form a complete package. This carton style is commonly used for gift boxes, apparel packaging, and specialty items. They provide a high-end look and feel, making them suitable for retail environments and promotional campaigns. Two-piece cartons offer durability and protection while enhancing the overall customer experience through premium packaging solutions.

By exploring different types of carton boxes and their unique benefits, we can help you find the ideal packaging that not only protects but also promotes your product effectively. While the above carton types are the most common base designs, they are not a limitation. Our design team can work with you to create a unique, innovative packaging solution for your product that will stand out on the shelves. Talk to a packaging expert today to get started finding the right types of folding carton boxes for your packaging.

Even for experienced industry professionals, printing and packaging terminology can seem unclear at times. At JohnsByrne, our aspiration is to simplify that aspect of your business so you can concentrate on creating great products.

This style features closure panels on both the top and bottom that swing from the front to tuck in the rear. The Straight Tuck Carton is the most universal and ideal canvas for a multitude of products and allows for maximum flexibility of finished.

The Reverse Tuck Carton has a top closure that tucks in the opposite direction from the bottom closure. The SRT can be assembled through automation or manually and provides secure and easy closure. Tuck Cartons are typically used to package lightweight products. These cartons are typically shipped flat to the manufacturer, which makes them easy to transport and store.

The French Reverse Tuck differs from the Reverse Tuck in that the top closure hinges off the front panel and tucks to the rear, while the bottom closure hinges off the rear and tucks to the front. French Reverse Tucks can have a slit bottom and a friction lock top. Other common combinations are slit lock top and bottom and friction lock top and bottom. This would be dependent on the weight of the product and opening experience preferences.

This pre-glued folding carton has a bottom constructed from multiple folded flaps which are positioned to form a composite bottom panel when the carton is assembled. The extended top flap is tucked in and held in place by friction or locked in position. Tucks may have either a friction fit or slit locks for a more secure closure. The glued bottom also allows the box to support heavier products and quick assembly.

This type of carton provides a glued closure like the Auto Bottom above. It is designed for quick assembly and is typically designed for heavier products which is better supported with the large internal base panel. For example, sets of hair care products, or a wine and spirts VAP set (Value Added Package).

Sometimes referred to as 1-2-3 closure, it is used almost exclusively as a bottom closure, generally in combination with a tuck top closure. This is a hand-erected and closed style. This style is commonly used as the bottom closure for shallow, tube style products. The Snap Lock Bottom offers additional security and is ideal for heavier products. This carton style fills the gap between a Tuck Bottom and Auto Bottom Carton in terms of cost, strength, and assembly.

This style is modeled after the straight tuck carton and contains and extra fold out panel, referred to as the 5th panel. This additional panel is use for extra copy and a replacement to additional printed pamphlets or brochures in the package. Window elements can be added to this panel to create creative show-through elements as well to complement brand identities.

A Finished Edge Slipcase can be used when an open end is preferred. The most memorable exposure one would have to this piece would be a DVD or Blu-ray collection. Some other use scenarios would be having a sleeve over the top of a side load Finished Edge Slipcase. Also, a combination of two slipcases with one of them being shorter than another would lead to a nice sideload package with reveal.

A sleeve is often used to keep a package closed (ex: a two-piece box) or can be used to cover a tray (ex: a slipcase or frame view tray). It can also be used for extra graphics or a limited time promotional copy on the exterior or an existing package. For example, during a holiday promotion it can be used, then removed once the promotion ends.

A front lock mailer is a an easy-to-assemble glueless carton that provides protection to the package and contents inside. The tabs on the variation shown form a secure closure. This structure can be highly decorated using premium finishes and materials to bring it into the luxury space.

Custom box inserts, also known as packaging inserts or packaging inlays, are used to ensure your products are secure inside your box. These can come in the form of paper inserts, cardboard inserts, or foam inserts. Other than product protection, custom inserts allow you to present your products beautifully during the unboxing experience. If you have multiple items in one box, packaging inserts are a great way to position each product just the way you'd like.

Creating an ideal insert design is more than meets the eye. Because products come in various shapes, sizes, and weights, it becomes crucial to use the appropriate materials, construct robust structures to securely accommodate each item, and ensure a precise fit between the insert and the outer box to complete the package.

Working with PackMojo was an absolute breeze. It can be intimidating working with a company overseas but Vincent helped me execute my project perfectly. The final custom boxes and inserts are incredible!

PackMojo is now our go-to for custom corrugated boxes! From packaging development through production, freight and quality assurance, their project management, expertise and professionalism are simply unmatched. Plus, they offer a wide variety of recycled and eco-friendly materials, in addition to a tree planting program. Highly recommend!

With custom box inserts, there's no 'one size fits all' solution. The structure of an insert is tailored to accommodate the size, weight, and position of each product, ensuring optimal security. Here are some examples of common paper or cardboard based insert structures.

Box inserts that are corrugated (the wavy lines in cardboard) are stronger and ensure the insert is sturdy. Corrugated inserts are typically used for heavier items, fragile items, or items that will be shipped and need extra cushioning/protection.

Box inserts that are paper based and not corrugated are typically used for lightweight, non-fragile items. These paper based inserts used a standard thickness of 300-400gsm, and contain at least 50% post-consumer content (recycled waste).

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