Packaging Design Part 2

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In Part 1 of the Packaging Design series, I showed how to prepare the figures and tray for a custom package. Today I am going to show you how to complete the final product. Here is how the figures in their tray, sitting in the package with holes cut out, and a sheet of red construction paper behind them:

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At this point I have already designed the graphics in Photoshop, and arranged them to be printed on an 11″x17″ sheet of glossy cardstock paper. It is important to use cardstock paper, otherwise the graphics underneath will bleed through. Also, using a glossy finish paper makes it look more like an official product. Use the highest quality print settings, and print at least two copies, in case you screw up. You will need a hobby knife to cut the inside squares out, but you can use a sharp scissors for the outside. Here is how the front of the packaging looks once it is cut out:

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The next step is to fold the packaging along all of the seams. You can fold it along the edge of your desk to help get a straight line. A few small cracks might appear at these seams. For this reason, I make these areas black in the design, so I can touch them up with black paint afterwards. Once everything is folded, wrap it around your package once to make sure it will fit correctly. You may need to trim some areas, including the window area on the old packaging.

Once you are certain it will fit correctly, lay the old package on top of the printed graphics and trace the shape of the peg hook. Cut this out with your favorite pointy tool. Now we are ready to glue it on. I use rubber cement to attach the graphics to the old package. I have tried other glues, such as white Elmer’s glue and superglue, but these bled through the paper.

The front area with the windows is the most important area, so start there. Put a thin coat of rubber cement on the inside of this area of the printed graphics, paying special attention to the edges and corners. Now press this down onto the old package and position it correctly. Apply pressure in several key places using the fingers on both hands. Hold this for about 30 seconds, then shift your fingers to other areas and hold for another 30 seconds. Now you can repeat this process with another area of the packaging. Keep working your way around until all parts have been glued on.

Now if you look in the seams, you might see part of the old packaging underneath. This is another reason I use black graphics around the edges. Get a small paint brush, and lightly brush some black paint inside of these seams. You could even do this before you glue the graphics onto the package.

Give it a few hours to dry, and then check to make sure all of the corners have been properly glued down. You might need to put some more rubber cement under a corner using a toothpick, and then hold it down for one minute or so.

Now stand back and admire your finished product!

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3 Responses

  1. Hellpop says:

    I saw this when you posted it on eBay recently, Luke, and was mighty impressed. Of course, if this were a DST product I’d be saying “Where’s the Falcon?”, but you get a pass :).

  2. deadpoolfanboy says:

    I want this! I need this!

  3. Bob Harris says:

    Where is the Falcon?

    Just kidding, you already got my “review” on that outstanding work. And thank you very much for giving us usual mortal customizers those insights. 😉