Evokar
A smart package design solution that folds and assembles straight off the press. Using only corrugated cardboard to house lampshades for shipment, this design features a single joint on the outer box and an assembly of slotted interior forms to cushion the lamp shades and strengthen the structure of the box.
At first the lampshades were measured precisely from their molds, referencing their images in CAD software to get their shape and dimensions.
Design and Prototyping
The idea behind this design is to create a packaging solution that is easy to assemble and disassemble, and is also easy to store and transport.
The design is inspired by the origami art form, and the idea of folding and unfolding a box to create a structure that is both strong and light.
Exterior Form
The boxes were classified into two categories based on the dimensions of the lamp shades. A few changes were made in design i.e. smaller top flaps and a heptagon base to account for better stability, while also keeping the form.
After the design was resolved, making the working drawings for cutting was the next step. Unwrapping the box gave us the result above, which was then modified to fit into the available material sheet.
Interior Forms
Once the box was ready, Interior forms were designed which served as a protection case for the lampshades. The horizontal disks prevent the box from bending or deforming and keep the product in place, while the vertical ribs hold the structure together.
To complete the assembly of the interior forms structure, there are 7 identical vertical pieces and 4 horizontal disks that follow the shape of the product.
The design of the interior forms above produced a lot of wastage, to counter this another option was designed, breaking the horizontal disks further into equal parts that locked onto two vertical ribs individually, This allowed for a lot less material waste but increased the cutting cost as well as labour.
Although this option was not used in the final production, the idea was worth mentioning and may be viable in other cases of mass production.