For this project we were tasked to create a set of chocolate bar packaging designs for a fictional brand focused on sustainability and ethical causes.
Problem
My design for my brand called “Relik” revolved around creating a distinct shape utilizing pressed paper pulp packaging. This method is unique not only for its ability to create new shapes but because it utilization of recycled materials. This method is traditionally used for egg cartons and interior packaging structures because it is a low cost, and high volume approach to manufacturing.
To realize my design and explore this process further, I created three rough physical prototypes using 3D printed molds. This research required extensive experimentation and trial and error to get a repeatable process. This approach I will be sure to revisit in the future as I have developed a way to get results each and every time.
Skills
Rhino
Keyshot
Illustrator
Photoshop
3D Printing
Prototyping
Mold Making
Vinyl Cutting
Design
I wanted to make a chocolate bar that felt more like a piece of technology than a consumable good, packaging you keep even after eating the candy
Prototyping
Through much trial and error I created a repeatable process to create packaging using pressed paper pulp.
Front
Back
Press
Molds
I modeled and 3D printed molds out of heat resistant resin. The mold consists of three parts, front, back, and a key press with channels for flow.
Pulp
I created my pulp by blending shredded cardboard, pigment, and eco friendly glue to create a material that was recycled and biodegradable.
Press
After I filled the molds with pulp, I used the press piece to compact the pulp into shape, letting the water escape through the channel holes
Cure
Once the pulp is pressed in place, put the molds into an oven to cure and harden the front and back pieces of the packaging
Combine
After both sides have been cured, remove them from the molds, glue them together, and add the labels cut using a vinyl cutter.
Prototypes
I created a set of three physical prototypes using this pressed paper pulp method and hope apply this approach to projects in the future!
