Description
Cara Clip is a vacuum-formed packaging project designed to hold and display a 3D-printed carabiner. The packaging includes a two-layer blister design, similar to retail packaging for small products, showcasing the carabiner while protecting it during transport. The carabiner itself went through multiple design iterations, transitioning from experimental moving parts to a static form optimized for the project’s scope. The final product reflects expertise in mould-making, vacuum forming, and creative packaging techniques.
PROJECT PROMPT
Design and create a two-layer blister package to securely display a small product, such as a 3D-printed item, in a retail setting. The packaging must protect the product during transport while maintaining a professional and polished appearance. The objective was to utilize vacuum forming techniques and mould-making expertise to produce a clean and functional design.
PROCESS
Inspiration
The Cara Clip’s packaging design was inspired by retail blister packs, such as those used for Hot Wheels cars. The goal was to create a clean, professional-looking package that effectively displayed the product while offering protection. The process also focused on minimizing visible imperfections and tool marks, ensuring a high-quality finish.
Initial Sketches
Sketches were created to explore potential layouts and configurations for the packaging. These early concepts considered the overall shape, visibility of the product, and practical assembly methods. Ideas ranged from simple outlines to more intricate shapes tailored to the carabiner’s form.
Mould-Making
3D-Printed Moulds
The moulds were developed from the Cara Clip’s CAD model, leveraging 3D printing for precision. Initial moulds had tight tolerances, leading to difficulties in removing the formed material. Iterations included adjustments to the draft angle and the addition of pull tabs for easier removal. Final improvements ensured the mould could withstand the vacuum forming process while maintaining detail.
Air-Dry Clay Moulds
As a backup, air-dry clay moulds were created. While concerns about shrinkage and symmetry initially made this less appealing, the clay proved reliable for heat resistance and allowed for manual refinements.
VACUUM FORMING
The final mould, made from PLA, underwent a smoothing process to prevent 3D print lines from transferring to the plastic. A layer of styrene was vacuum-formed over the mould first, creating a smooth surface. A second layer of clear plastic was formed over this base, resulting in a polished final product. Multiple tests were conducted to refine fit and ensure the design achieved the desired aesthetic and functional qualities.
PACKAGING
The back card design was printed with full bleed and laser-cut to precise dimensions. It included a front and back layer glued to the vacuum-formed plastic, ensuring clean edges and a professional appearance. The assembly involved careful alignment and adhesive techniques to hide seams and secure the blister components to the card.
FINAL PRODUCT
The Cara Clip packaging showcases the carabiner in a secure, professional-looking display. The two-layer blister pack provides protection and visibility, with a clean design achieved through precise mould-making and finishing techniques.
REVIEW & LEARNING OUTCOMES
The final product exceeded expectations in quality and presentation. However, future iterations could explore stronger materials for the carabiner and more luxurious packaging designs, such as box formats. Key learnings included techniques for hiding imperfections in vacuum-formed plastics, improving mould tolerances, and mastering plastic assembly methods.
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