The Corner Project
September 24, 2019
The objective of the project consisted of exploring the different ways to create a corner with cardboard. This allowed us to explore the capabilities and limits of cardboard as well as the adhesives that we can use with it.
Corner #1
I started off with a basic approach, creating an L-shaped net and a flap to join the seam. I joined this piece with double sided tape, but it wasn’t very sturdy. After a few days the tape lost its adhesive and the corner fell apart.
What I didn’t like about the joining seam was the corrugated cardboard cardboard showing. It was a sharp contrast compared to the folded seam. I decided to address this issue in my next draft.
Corner #2
For my next corner, I used the same net I created for the first corner and stripped the flap to the thinnest layer of cardboard. Then, I tucked the flap into the corrugated cardboard inside. This was a little difficult to do, and the seam, though less obvious, still stood out compared to the rest of the folded sides. I used a glue stick as the adhesive, and it hasn’t fallen apart, unlike the first one. I think the mistake in this work is that I should have tucked the flap in the top layer of corrugated cardboard, not the bottom layer.
Corner #3
To mitigate the issue of the contrasting seams, I decided to just make all of the seams the same. Instead of making the corner with one cardboard piece, I used three pieces this time, using notches as the seam. In the end I liked the consistency of this corner, and it also felt sturdier. I also used a glue stick to adhere the corners, and it has surprisingly held up very well.
Making the Macaron
September 26, 2019
The process of making the macaron out of cardboard was just as tedious as making a real macaron. Because all of the aspects of the macaron are round, it was very hard to achieve the same effect with cardboard.
Macaron #1
This was my first attempt at the macaron. To achieve the puffiness of the cookie, I glued together two disks of cardboard together and wrapped it in the thinnest layer of cardboard. This part was difficult, and I used a lot of glue to keep the thin layer in place. I then sanded down the cookie with sandpaper I borrowed from my classmate. To create the feet of the cookie, I gathered the thin wispy strips I had lying around and wrapped it around the bottom of the cookie. To create the filling, I wrapped and glued scraps of cardboard in a thin layer of cardboard and sanded it into a round shape.
My first attempt set the precedent for future drafts. This experimental macaron also helped me find ways to repurpose scraps of cardboard, thus reducing the amount of cardboard and waste I created.
Macaron #2
While making my first macaron, I had struggled with wrapping the thin layer around the two cardboard disks to create the cookie. To help with that, I decided to cut the sides of the thin layer to help it wrap more evenly. The process of wrapping it was much smoother, but when it came to sanding, since there was only one layer, the cardboard ended up ripping and exposing the inside corrugation of the cardboard. I also changed my approach to the feet of the macaron by using a disk of cardboard and exposing the textured corrugation. I don’t think this was as effective, since it’s more difficult to see compared the the previous attempt. I kept the same technique I used for creating the filling, because I found it very effective.
Macaron #3
For the third macaron, I merged what I liked about each macaron that I made. I kept the wrapping technique, because I liked the smooth sanding that it allowed. I also used the same filling, since it worked and didn’t cause any problems.
For the macaron’s feet, I liked the texture of the corrugation from the second macaron, but I wanted it to be more visible. I proposed to make a ring and tuck it over the whole cookie. I don’t think I executed this plan very well, because it was very hard to cut round, thin pieces of cardboard without it wrinkling or ripping. This was a very good lesson for me to learn for future projects.
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What I Learned:
- different ways to use the different elements of cardboard, from the layers, to the corrugation, to even the scraps left over
- how to analyze an object’s features and communicate them effectively with simple cardboard shapes
- the limitations of cardboard, like its inability to be cleanly cut into thin round rings
- I worked on techniques that allowed me to cleanly rip off layers of cardboard without damaging them
- this project honed my problem solving skills, and allowed me to judge what actions to take with the material I had
Prototyping Carrier Features
October 1, 2019
I started off this project by listing out aspects of macarons that needed to be protected in the packaging. That consisted of the delicate cookie and the soft filling inside the macaron. I concluded that there couldn’t be too much pressure on any part of the macaron, or else the cookie would crumble or the filling would get everywhere. In addition, the filling would most likely stain the cardboard if it were to get onto the cardboard.
I also googled examples of good macaron packaging and sketched the ones I liked down. In addition I sketch some packaging I liked outside of macarons to draw out some additional aesthetic inspiration.
What I Noticed:
- Most of the macaron packaging store the macarons vertically. I inferred that vertically placing the macarons makes it easier to take out of the box.
- Some of the macaron containers don’t use dividers — but to protect the macarons I still think it’s necessary.
- Good packaging is typically really simple and minimalistic with a unique/subtle flare to it.
Carrier #1
I started to plan out the box by sketching out a basic box first. From there I made a box that had all the flaps fall down, creating a dramatic presentation for the macarons. This package consisted of many moving parts, and I was wary of my ability to execute this plan.
My second sketch consisted of a box with a diagonal flap closure. This was much simpler than my first one, and I liked the diagonal that was created on the side of the box, for it added a subtle decoration to the simple box.
During the process of making the macaron box, I applied some of the knowledge I gained from making the cardboard corners to the box. Through creating this box, I learned how to make dividers for the macarons that easily slide in and out of the box as well as being snug. The grooves for the dividers were made along the corrugation of the cardboard, creating the perfect slot for the dividers.
I also really liked the compactness of the box — it reflected the smallness and cuteness of the macarons.
I went through a lot of trial and error while constructing this macaron box. The first error I encountered was not taking in account the size of the whole box laid out. Towards the end of drawing and measuring out the net of the box, I realized that one flap ran off the cardboard. In the end I had to Frankenstein a piece of the box that I shouldn’t have had to. Also, there was a lot of empty space between the dividers and macarons, causing them to jiggle around in the box too much. The walls of the dividers were also too tall, making it a struggle to take the macaron out.
Carrier #2
I addressed some of the issues in the plan for the next box. I wanted to create an even more compact box, for the previous box still had some wiggle room. This would have made the box even cuter, reflecting the macaron’s cuteness, but it did pose a lot of problems.
For the second box, it was a little too snug, and I couldn’t fit the dividers in. Earlier, I had concluded that dividers were necessary, because that would protect the delicate cookie of the macaron more effectively, so this wasn’t ideal. For future reference, I learned that it was necessary to not use exact measurements for the compartments, or else it would be too snug. Despite the failures, I did learn how to cleanly remove the layers of cardboard. I scored the cardboard into smaller sections and it ripped off a lot cleaner.
Carrier #3
I wasn’t happy with the previous boxes, so I decided to change gears and make the very first plan that I made. I liked how it presented the macarons in a dramatic fashion, and the latch was really unique. I did miscalculate on how many surfaces the triangular top flap needed until after I cut it out, so I had to scrap that in the end. Even though this box didn’t follow the plan, within my peers, this one received the most curiosity and attention. They really like the clean and curved latch.
Though it was well received, it did have its fair share of problems. To address the problem the dividers gave in the first box, I created divots for the finger to go in to make it easier to take the macaron out. However, the dividers were too snug, and as a result the divots didn’t serve that much of a purpose.
Expanding on the Carrier
October 3, 2019
Critique
During the critique in class, we discussed how the carrier should reflect what the object is inside. My box shape was too angular compared to the delicate and round macaron. When closed, though it had a curved latch that alluded to the elegance of the macaron, it did not give any other cues to what was inside.
I also had to consider the interaction of the carrier. The macarons had to be a lot easier to take out, since if it is a struggle to take the macaron out, the user may damage the macaron.
The New Carrier
For my new design, I decided to round the edges of the box to give it a more elegant and professional look.
To emphasize the roundness of the macaron, I decided to make the dividers a curved shape, functioning as both a place for the finger to hold the macaron and as a way to show the characteristic of the macaron.
A peer suggested to create a cutout to show off the color of the macarons. I created a swirly cut out of the letter “M” that showed the elegance of the macarons as well as showing off their color.
Because I’ve had a history of making wrong measurements on the carriers, I started off by creating a paper mock up of the design, to make sure that I got all the measurements correct. I think this was helpful in developing confidence before cutting the actual cardboard, as well as judging if everything would work out.
While creating the carrier, I used some new techniques as well as some old ones. I kept the slots for the dividers as well as the tab technique I used while creating the cube corners. I also used the technique earlier to cleanly rip off the layers of cardboard. To make sure that all the curved walls and dividers were the same, I created a paper template to make sure that there wouldn’t be any inconsistencies.
In the end, the carrier turned out a lot boxier than I had expected. I believe this was attributed to the limits of cardboard. The thick cardboard didn’t do too well with detailed scoring. This was an instance where the paper model didn’t transfer well onto cardboard.
Additionally, with the layers of cardboard stripped on the lid, it became very weak and couldn’t withstand pressure from the top. This could easily become a hazard for the macarons, for they can become crushed easily.
In-class Critique
What I learned:
- The decorative “M” is a crutch because the box itself cannot communicate the contents of the carrier.
- You can go further than just a rectangular box. Make the outside shape of the carrier more descriptive. Think outside the box!
- Adding material weakens the structural integrity of the cardboard, and it makes it less cohesive as well — take a more deductive approach.
- By only cutting out 3 sides of a window and folding the rest in, you provide an opportunity for a window and a divider/another feature without weakening the cardboard.
- Build cues on how you want the user to hold and interact with the object.
- Keep the user curious, how much do you want them to see?
After the critique, I concluded that I needed to make my carrier much rounder to reflect the shape of the macaron. Though the “M” was a crutch, it did do a good job at identifying the top, bottom, and front of the box. I will have to work on creating a new identifier that doesn’t involve a crutch.
Carrier Draft 3
October 7, 2019
Improvements/Goals
- Don’t use adhesives
- Use a cylindrical or round shape to allude to the shape of the macaron
- Minimize the amount of pieces used — use windows as cutouts
- Approach the carrier design creatively
Attempt #1
I really wanted to create a carrier that doubled as a great presentation piece at the dinner party, and I wasn’t sure if a cylindrical carrier could achieve that. I decided to explore an explosion-type carrier that would spread out with the macarons in a flower-type form, pointing at the four corners. However, while making the paper form, I noticed that the carrier required a lot of flexibility to create the smooth bubbly shape. Also, the notches at the top of the box may become too layered with cardboard, which would become a problem while translating it to the cardboard form. I decided that this idea, though cute and unique, did not do what the cardboard wanted to do, so I began to explore other ideas.
Attempt #2
In my second attempt, I tried out an octagonal shape that rolled out to display the macarons. Because the curved latched box that I made in the beginning was so well received, I decided to recreate it in this attempt. I also made notches on the sides of the box to keep the rolled section of the box intact with the octagonal walls. In addition, I designed triangular cut outs on the side that would act as dividers. However, the overall design did not fair well, and the carrier constantly fell apart.
What didn’t work:
- The curved latch design didn’t fit properly, because it constricted the latch from successfully fitting together.
- The notches didn’t fit together well — probably because they were too small. The small notches tended to fray, weakening the strength of the cardboard. I will definitely have to approach this concept differently in the future.
- The dividers I created from the windows were flimsy as well. This met a similar issue as the notches, because the cut out was too thin, which made very unstable dividers. Also, when the carrier is open, the dividers came out and did not effectively hold the macarons in place.
Attempt #3
For the third attempt, I decided to make a cylindrical version of the fourth carrier that I made.
I had tried creating an overlapping curved latch as seen in my plan, but due to the thickness of the cardboard, the latch didn’t slide very easily together, so I removed the top latch, leaving the bottom one to hold the top flap in place.
I decided to keep the curved dividers from the fourth “M” box because it was comfortable to use and was well received.
I also tried out the method many others in class used to create a cylindrical shape. Instead of scoring from the inside like in the previous carrier, I tried out scoring from the outside. I decided to score the cardboard against the corrugation to keep the smooth slots for the dividers created by the vertical corrugation. What was interesting was that scoring against the corrugation made the cover only curl in one direction, whereas if it was scored with the corrugation, it would have been more flexible. I also should have made my scoring more consistent, because as seen in the first picture, when on score line is heavier than the others, it shows up quite easily.
To address the no adhesive requirement, I tried to use inserts and tabs, but that didn’t work out well because I was working with such a small surface. The tabs and notches easily ripped, and I had to tape it back together.
Speed Dating Critique
October 8, 2019
I brought the “Attempt #3” carrier to the critique, for I believe that it held the most merit, because out of the two “cylindrical” carriers that I have made that truly reflect the shape of the macaron, the 3rd attempt is the only one that could somewhat keep the macarons in place and stay latched.
Issues Observed:
- The carrier fell apart often when being opened due to the weak notches used.
- The macarons tended to roll around once opened, as well as the dividers sometimes.
- The protection of the macarons was iffy.
- The latch is off centered, and the purpose of it is unclear (the hooked shape).
- The scores folded inconsistently.
- It reminded people of the Krusty Crab, which was not the intent. Also, as a result, people associated the macarons with Krabby Patties.
Positive Observations:
- They liked the circular form, and noted how it reflected the shape of the macarons.
- Many commented on the cuteness of the carrier.
- The slots made for the dividers was satisfying.
- The carrier rolled back when opened, giving an interesting presentation of the macarons. (Happy accident?)
Next Steps:
- Create a larger carrier, for that would be able to handle notches without ripping. Also, it could possibly highlight the daintiness and fragility of macarons when opened, for they would be dwarfed by the box.
- Add additional walls on the back and sides of the macaron row to prevent them from rolling around so much.
- Score the carrier along the corrugation to make it more consistent, because it has a more defined deepness to it. When it’s against the corrugation, it’s more prone to different thicknesses of scoring.
- Explore different notches/latches.
- Add more cues.
- Think about the presentation of the different states of the carrier.
- People like the interaction aspect of packaging, whether it be the sound or an unexpected pop. Consider adding some of that in the packaging.
Finalizing the Carrier Design
October 10, 2019
I started off by writing a pros cons list of the two previous carriers I made. I was actually surprised by how little pros the second carrier had, even though I brought it to the last critique. I found that I liked the idea of the first carrier better even though the second one was more functional. As a result, I decided to merge the uniqueness of the first carrier and the functionality of the second carrier together.
I managed to create the carrier with one piece of cardboard, with exception of the dividers. Instead of using the window-cutout technique for the dividers, I decided to use it as side walls, with the dividers holding the walls in place.
I also allowed more space between the side of the cardboard and the notches, which helped greatly, because the notches did not rip when the tabs were put in. Also, they were made against the corrugation, which made them stronger.
To double the practicality of the walls, I designed a curved wall that doubled as an allusion to the characteristic of a macaron as well as something that kept the dividers from sliding along the wall. I also created the slots for the dividers on the bottom as another precaution to that problem.
I also decided to score the cardboard on the inside to create a cleaner look on the outside. When I created the previous two carriers, I experimented with which side to score. I like the clean look caused from scoring on the inside, so I decided to go with that instead. When I scored on the outside, the carrier reminded me of a log cabin.
I also played around with the corrugation of the cardboard within the dividers to see which divider was the strongest. I found that the vertical corrugation tended to be more flimsy, which made sense, because there wasn’t as much support compared to the horizontal corrugation.
However, the dividers did come with a flaw, for they were only grounded by the bottom slot. This allowed the divider to move around a bit too freely, causing instability. When it comes to macarons, it’s not a good idea to have dividers that didn’t fully fulfill its purpose, for they could get damaged. In the future, I will add slots to the sides of the walls as well, grounding it on three sides instead of one.
In the end, this was the result. One major flaw of the carrier is that the latch is difficult to use. The scoring of the hexagonal shape could have been cleaner as well. I will definitely address these issues in the next iteration. Other than that, I believe that I have a good start towards my final design. The carrier is very easy to assemble, and is made up of simple objects.
A unique element of the carrier that I found interesting was the little pop the side walls made when the carrier was opened. Many people commented on how they liked the reveal when opening the carrier, for not much is revealed on the outside about the surprise inside.
Another thing I quite liked was the presentation of the carrier when opened, for the cutouts on the bottom give a floating effect to the macarons. I didn’t plan for this to happen, but I really like how it turned out, especially the fact that this accentuates the macaron’s luxury and delicateness.
The Final Critique
Comments and Observations of the Carrier:
- When observing people opening and closing the carrier, they seemed to have difficulty aligning the small notches when putting it back together.
- They also had difficulty in figuring out how to open and close the latch on the top.
- There is no clear cue on how to hold the box, and many may accidentally hold it like a tumbler (vertically) which is not ideal, especially when considering the delicate nature of macarons.
- The latch and the small notches were noted as actions the cardboard is not “happy” in performing.
Next Steps:
- Implement an obvious cue on how to hold the carrier, like a handle.
- Use a new approach to the closure — maybe implement it into the handle?
- Find a more comfortable and obvious way to use the notch, one that the cardboard is “happy” and users can intuitively use.
The Final Product
October 15, 2019
For my final draft, I decided to focus on the two main issues of my last carrier that still needed to be solved — the notches and the handle. I noticed that I could use the window-cutout technique to create a handle as well as a cover/latch over the carrier. This would adhere to my goal of keeping the main piece in one piece to keep the assembly simple.
As I was figuring out how to latch the top of the carrier together, I played around with some closures. I needed one that didn’t give false cues like in my previous carrier. My first thought was two notches sliding together. I tried it out with scrap pieces of cardboard first, and I found that the notches were happier in a protruding “X” shape. This wasn’t ideal, for it would get in the way of the hand using the handle.
I decided to settle with an idea inspired by my previous latch, a snug closure that closed like a jigsaw puzzle. This later turned out to be an issue.
To address the notch issue, I thought about creating a larger notch, which would make the cardboard “happier” as well as making the cue to the assembly more obvious. However, the sketch I made reminded me of ears, so I decided to think of another solution. I then remembered that the slots that I have been creating for the dividers held the cardboard in quite well. This would be perfect in creating a more seamless design, for you can’t see the notch on the outside. I believe this idea was a success, and it couldn’t have happened without my work with the dividers.
The process of creating the carrier was fairly straightforward, but the functionality was not. Due to some of the choices that I made, many issues surfaced.
Unlike my previous carrier, I created this carrier with a vertical corrugation. This was due to the fact that I would have many slots in one direction, and it was easier to create those slots by cutting it along the corrugation. However, a couple of issues surfaced.
One was that on the edge of the carrier, there was a thin stretch of cardboard. Because of the vertical corrugation, the thin stretch was held up by one corrugation inside. This made it easily collapse and flatten, making the notch for the walls very ineffective. The hexagon walls would constantly come out of the notch.
The other issue was similar to the first. There were many thin strips of cardboard along the corrugation, and when cut, they frayed off because there was no corrugation supporting the strip of cardboard.
Another issue regarded the latch system at the top of the carrier. It did not work at all, because the overall carrier was fairly loose and relied on the latch to keep it together. The latch I had used was for the opposite situation (a secure base can afford a loose latch). As a result, it did not hold the carrier together at all.
I was back to the drawing board, but I learned from my lessons. I redesigned the latch with a tab that inserted into a slot. I also changed the corrugation, for it would greatly improve the quality of the side notches as well has making the carrier much stronger.
In addition to the notch and latch improvements, I also addressed the issue of the wiggling dividers. To deal with this, I cut slots on the bottom and side walls, creating a thin piece of cardboard on the sides. I then created the same dividers but with smaller slits. This method worked very well, and the dividers are very stable now. I’m glad that I was able to improve the divider, allowing it to serve its purpose of protecting the macarons.
Another problem that occurred were the two prongs that protruded from the handle. I had kept it for it was the template to the latch, and I hoped that it would double as an interesting decoration as well. However, it instead got in the way of the user’s hand when they were using the handle. I decided to cut these parts off to make the handle more comfortable.
My carrier ended up using a total of 6 pieces, 5 of which are repetitions of each other. As a result, the assembly is very straightforward and simple, and can take under a minute to assemble and disassemble. I find this aspect to be a success.
I liked the ease of opening a lot more compared to the previous carrier from October 10th. Also, the “pop” of the side walls that I liked from that carrier is more dramatic here, and as a result I find that this carrier has much more of a surprise element. I believe that this is a plus to the carrier.
Conclusion:
When we started off with the cube corners, I had no idea what we were getting into. I found the task fun but simple, and as a result, I didn’t prepare myself for what was to come. If I had known, I would have experimented much more with the limits of cardboard, as well as exploring non-adhesive strategies of linking cardboard together.
This project really tested my patience. Because macarons are so small, I had very small material to work with, which is consequentially very prone to ripping. This wasn’t a huge problem in the beginning, for we could use adhesive. Hot glue was my best friend during that time. However, once that crutch was removed, all of the problems arose, and I ended up failing many times. Through this trial and error process, I managed to learn the limits of cardboard when at a small scale and how to work around that.
Another thing I had to struggle with was how to allude to the shape of the macaron on the outside of the box without decorations or diminishing the curiosity of the user by exposing too much, all while creating a user-friendly, unique box for the macarons. All these elements were very difficult to balance. There was always something to fix and improve on, and the critiques helped bring those to light. Through these critiques and talking to my peers, I was able to find some sort of balance in the design of my carrier.
This process has taught me a lot about the importance of the process of experimenting, planning, and revising. Experimenting allows one to explore all the limits and know what to do and what not to do before wasting time by applying it to the real deal. It also stops you from doing things outside of the material’s limits. The planning was also very instrumental in designing the carrier, because it allowed one to explore and visualize all the ideas before getting their hands dirty. I also I never thought that I would need to use trigonometry in this project, but I had to to draw out the perfect hexagon for the net of the carrier. The process of revising was also very rewarding. The feedback from both the professors and my peers were always insightful, and in turn, giving the feedback was an enriching experience. Personally, the feedback helped bring things outside of my tunnel vision and into the bigger picture. It was satisfying to slowly see everyone’s carriers improve as a result.
