Initially i wanted to laser cut the plastic as the polypropylene was 2mm thick. However i had no assess to a laser cutter that was large enough to cut out the template. So i then had to measure and cut the plastic by hand.
With help i used steel rods and clamps to ensure the plastic didn’t move so that i got a clean cut. I also tested glues to see if they were transparent and strong enough to hold the plastic lid together.
For ease i varied a little form my original flat design and chose not to cut two thing slices up the slides of the lid instead i cut a basic square.
After researching for similar packaging to what i need to develop i found that there wasn’t many existing packaging.
I knew i needed a packaging that would open out flat and that was strong enough to support the weight of the blocks.
I also thought a transparent packaging would be an effective selling point as people would eb able to see the detailed laser cuttings on the exterior of the blocks.
When i research different plastics and contact some local plastic companies i was advised that polypropylene plastic would be best suited to what i was looking for. Polypropylene is easily cut and bent which was beneficial to me as i was making a unique packaging.
Flat Design of Packaging
I then developed a prototype, scaled down to fit one cube. I did this to see if there were any structural flaws with my design.