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STEPpack

 

LINE Graypants

DISCIPLINE product packaging

YEAR 2014

ROLE ideation, concept development, prototyping, user research, testing, design for manufacturing

ELEMENTS flat-pack shipping, user experience, unboxing experience, recyclable at end-of-life

MATERIALS corrugated fiber board (laser cut, etched)

 
 
 
 

OBJECTIVES

  1. Develop a packaging solution for the Steplight pendant that minimized volume and maximized shipping efficiency. 

  2. Introduce no additional packing materials such as loose padding or foam.

  3. Create a memorable unboxing experience for the consumer. 

 

INSPIRATION

The Steplight pendant shade was cut from a flat sheet of aluminum. Before assembly, the aluminum shade had a material thickness of only 3/8”. This packaging project was driven by a desire to maintain that low profile.

 
 
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CONCEPT

The key to utilizing the low profile of the aluminum sheet was the fact that the consumer could easily assemble this product by hand, without tools or fasteners. This allowed the Steplight to stay flat until it reached its final destination.

The width of the STEPpack was driven by the diameter of the largest ring while the height was driven by the thickness of the socket. These factors established the maximum dimensions that all contents were stored within.

 
 
 
 

To aid in the assembly process, the packaging functions as a jig that guides the consumer through every step.

The unique layering system organizes the contents in an intuitive manner while eliminating unnecessary packaging materials and wasted space.

 
 

By reforming the material from a conventional, used box, a more efficient package is possible with STEPpack.

 

STEPpack uses only 20% of the space of a conventional box (shown on the far right, for comparison).

 
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RESULTS

  1. Using only 20% of the volume of a standard box, freight costs were reduced significantly. 

  2. Corrugate functioned as the container and the protection, eliminating all loose packing materials. Additionally, the corrugate used for the STEPpack could be resourced from old boxes that would have otherwise been recycled. 

  3. The unboxing process was an unique experience, highlighted by the intuitive jig function. 

STEPpack was honored by The Dieline with a packaging award in 2015.