Opal was preparing to launch their new product, the Tadpole camera. The product is much smaller than their previous generation, and they wanted to emphasize its mobility and ease of use. The same rule applied to their packaging brief. We aimed to create something compact, made entirely of paper materials. A major challenge was to manage the flexible cable and allow it to nest inside the packaging as well as ensure a stress-free unboxing experience.
We started by creating a 2-layer construction that hides the excess cable underneath the main tray, which showcases the product in its best light. The molded pulp trays, while able to afford a beautiful form cavity to house the product, have their limitations in creating complex channels and thin slits for the cable. Zenpack created a special die-cut tool for the narrow channels and created an “under tunnel” beneath the pulp tray that allows a pathway, making things easier for both kitting at fulfillment and accessing the product by the customer.
Due to an inherent production draft angle, it is difficult to achieve a snug fit with the molded pulp casings. Zenpack created a simple locking feature by folding a small paper structure that allows the lid to catch onto the bottom, creating a “clicking” feedback. We created a visually simple and intuitive packaging experience. But the work that goes behind the scenes was quite complex and refined. The packaging is fully recyclable and plastic-free.
