Project Overview
For the debut of their new disposable vape product, Live Cosmic Carats Blend, at the Champs trade show, Astro Eight sought a premium packaging solution that would stand out on the market. As the sole designer on this project, I was responsible for creating a custom 2-piece box consisting of a die-cut sleeve and an inner tray. This packaging not only needed to reflect the potency and elegance of the “Liquid Diamonds” additive but also had to meet practical constraints like shipping efficiency and legal requirements, including a child lock.
Role
Graphic Designer
Employment
Full-Time
Period
2023
Key Focus Areas
Branding/Packaging/Print
Context and Problem
Astro Eight is a hemp company that sells and distributes a variety of products, including disposable vapes, edibles, and pre-rolls. For their new Live Cosmic Carats Blend vape—featuring an extremely potent cannabis concentrate (Liquid Diamonds)—Astro Eight wanted packaging that would symbolize the product’s luxury and uniqueness while maintaining practicality. The packaging’s design would be showcased for the first time at the Champs trade show in Las Vegas, a key event for generating sales and interest.
The main challenge I faced was creating a die-cut diamond shape on the sleeve that would represent the product’s crystalline appearance. However, the complexity of the diamond cutout caused issues during production, as the manufacturer found the design too fragile to produce consistently.
(Initial Die-cut proposal)
Challenges Faced
- Intricate Die-cut Design: The diamond shape required by the client was highly detailed, which caused problems with the sleeve’s structural integrity. The delicate design made the packaging fragile, and the printer initially believed it would be impossible to produce within the tight time frame.
- Deadline Pressure: The packaging needed to be ready in time for the product’s debut at the trade show, adding urgency to find a solution that would balance creativity with manufacturability.
- Compact Design for Shipping: Another challenge was ensuring the packaging was as compact as possible to reduce shipping costs, a common requirement for product-based businesses.
- Legal Compliance: The packaging needed to include a child lock feature to meet legal regulations for hemp-based products, further adding to the complexity of the design.
Process
The design process began with measuring the dimensions of the new disposable vape device, ensuring that the packaging would be a snug fit without wasting material. I created a rough die-line and an overall design concept that reflected the elegance of the Liquid Diamonds product.
Using Adobe Dimension, I developed a 3D mock-up of the packaging, which allowed the client to visualize the print finishes, colors, die-cut placement, and overall size before we proceeded to production. This step was crucial for refining the design and making adjustments in real-time, saving time and cost before submitting it to the printer.
Upon receiving feedback from the printer, we encountered a significant roadblock: the die-cut diamond shape was too intricate for consistent production. The initial response from the printer was that it would be impossible to execute the design in time for the trade show. I worked tirelessly with the printer to adjust the shape, ultimately rounding the corners of the diamond and simplifying the die-cut to meet production requirements without sacrificing the visual impact.
Solutions Implemented
- Die-cut Adjustment: By rounding the corners of the diamond shape, I was able to retain the essence of the design while ensuring the packaging could be produced consistently.
- Added Protective Flap: I introduced a protective flap attached to the top of the inner tray, providing additional protection for the vape while also offering a neutral background for the diamond cutout to stand out visually.
- Metallic and Foil Finish: To enhance the luxury feel of the packaging, I added a drip motif representing the “liquid” aspect of Liquid Diamonds. This motif was highlighted using a metallic finish, which created a striking contrast on the sleeve. along with adding a silver foil finish to the logo to further push the brand.
- Child Lock: The design incorporated a child lock mechanism, ensuring the packaging met government and legal requirements for hemp products.
(Final Die-cut)
Results and Impact
The final packaging solution was a success. Astro Eight was pleased with the design, which helped distinguish their product from competitors who relied on standard packaging options. The sleek, compact, and eye-catching design played a key role in the product’s successful launch at the Champs tradeshow.
Following the launch, the Liquid Diamonds vape saw strong sales, and demand for new flavors quickly followed. The custom packaging not only contributed to the product’s commercial success but also helped reinforce Astro Eight’s brand as a premium provider in the hemp industry.
Reflection and Takeaways
This project taught me valuable lessons about the practical aspects of packaging design, especially the importance of balancing creative vision with manufacturing feasibility. The initial challenges with the diecut diamond shape highlighted the need for flexibility and quick problem-solving when working under tight deadlines.
If I were to approach a similar project in the future, I would advise clients to consider simpler diecut shapes, allowing more focus on print finishes and other design elements that can have an equally strong visual impact without complicating production.
Overall, this project helped me grow as a designer by deepening my understanding of packaging production processes and emphasizing the importance of collaboration with manufacturers to achieve successful outcomes.
