Evaluation of final four designs
Idea Aesthetics:
No: • The pop up display must have the logo
as well as the slogan.
• How easily the logo text and additional
info can be seen.
• How well it reflects price positioning.
• Dose it relate to my mood board
• How does it appeal to my target
market.
1 9/10
 I added a slogan to state my brands motto
and attract customers. I also added a
surface design to attract customers as it
relates pretty well with my mood board
and theme.
2 8/10
 The pop up display has the logo and I
will add a slogan as well to attract my
target market. The tree in my logo
relates to my theme of nature as well
as showing the customers that my
brand is environmentally friendly.
3 8/10
 Logo on the sides of the outer box allows
to attract the customer even if viewed
from different angle.
 Embossing the logo text also allows it to
stand out. The ribbon also has a pattern
and the brand name embedded on it.
4 7/10
 The color scheme relates pretty well to
my design specification. The logo, text
and the additional information can be
easily seen.
Costs:
• The logo should represent price
positioning ( Mid-Range).
• Does it contain any promotional
features.
• The cost of the wrapper should
be less than the price of the
product.
7/10
 The color scheme of my outer box
relates well with price positioning
of my product which is lower
mid-range.
7/10
 The contrast of my logo fits
with the price positioning of my
logo which is the lower mid-
range. The box also contains
nearly 20 bars which suits my
design specification.
7/10
 the color scheme and the
contrast of my logo and surface
design fit with my price
positioning well and appeal to
lower mid-range target market.
7/10
 The design of the logo reflects
price positioning and will be
able to attract the desired target
market. It contains a NEW
symbol thus enticing the
customers.
Customers:
• How does it appeal to my
target market (nature lovers).
• How convenient it is for the
customer to access, carry and
store the box.
• How well the customer is
informed about the product.
8/10
 My surface design depicts a
sunset in savanna thus relating it
to my mood board and appealing
to my specific target market
7/10
 By adding a finger slot my
outer box is now more
accessible for the customers.
The customers are well
informed about the product
and the ingredients used.
9/10
 A thicker and much bigger ribbon
allows easier access for he
customer to open the tray.
9/10
 Finger slot allows easier access
for the customer. Perforation also
allows easier access for the
customers as well as protecting
the product during transportation.
Environment:
• Does it contain a litter man and
Mobius loop symbol.
• How does the packaging have
minimal impact on the
environment.
• Does it contain 20% of recycled
material
• Can the customer use the box
for second time.
8/10
 The outer box contains a Mobius
loop and litter man symbol to
encourage people to recycle and
be environmentally friendly.
9/10
 I have added a mobius loop
and the recycling symbol at the
back of my product to
encourage customers to recycle
the product.
8/10
 The box contains the mobius
loop and litter man symbol
thus encouraging the customer
to throw the garbage in the bin
thus being environmentally
friendly.
9/10
 The outer box contains the Mobius
loop and the litter man symbol to
encourage customers to recycle
and be environmentally friendly.
Safety:
• Does it contain smooth edges
preventing the person from
getting paper cuts.
• Does the wrapper contain
warnings for chocking
hazards and allergies.
• Is the outer box durable and
sturdy to protect the product
during transportation.
7/10
 All safety measures have been
taken as the customers are
informed about allergy
information.
7/10
 All the necessary safety
measures have been taken
in order to insure
customers safety. For this
purpose I have rounded the
edges of my chocolate bar.
8/10
 I have added an extra tuck
and tab on top of my
vacuum tray so that it
protect the product during
transportation.
9/10
 It also contains a warning for
allergies and danger of
suffocation. I have also added
a warning for danger of
suffocation if the children use
my product.
Size:
• Is the logo large enough to
be visible form far away.
• Is the box size in
appropriate proportions
so that it fits the shelves in
the supermarket.
• Does the outer box hold 20
bars or more.
8/10
 I think my box is in the
right proportions to fit
the shelves of the
supermarket. Logo is
easily visible from far
away.
7/10
 The logo fits pretty
much 30-60% of the
front face of the box .
However, the number of
pieces of chocolates are
less than 20 which was
one of requirements in
the design specification.
7/10
 The logo fits pretty well
on my outer box on top
and on the side as well.
The outer box contains
exactly 20 bars which I
mentioned In design
specification.
6/10
 The logo doesn’t
properly fit the front face
of my outer box so I
might have to change it.
I also need to think more
clearly about the outer
box’s proportions so that
it fits the shelves in the
super market.
Function/Ergono
mics:
• Does the wrapper preserve
and protect the product.
• How well does the packaging
advertise/promote, inform
and identify to attract the
customers to buy the
product.
• Does it contain a slogan or a
pop up display.
9/10
 Perforation allows easier
access for the customers. I
have added a display window
thus allowing my customers
to easily see the product.
8/10
 The tuck and tab allows
easier access for the
customers and protects the
product during
transportation.
8/10
 The tab and slot makes it
easier for the customer to
open and close the box. The
ribbon also allows the
customers to pull the tab
easily thus making it easily
accessible.
7/10
 I will add a slogan so that
the outer box performs its
function pretty well.
Perforation makes the box
more secure and it only
opens when the customer
wants it to open.
Material/Manufactu Total Score:
ring:
• How easy it is to assemble the
packaging in the school.
• Are the materials used
environmentally friendly ( can be
recycled or are from recycled
source).
• How easy it is to recycle the
product.
• Does the material protect the
product from external factors.
( heat, water and moisture.)
8/10 64/10
 The shape of my product is a
cuboid so its easy to assemble it
in school. Ki used corrugated
card board as it s recyclable
making it environmentally
friendly.
9/10 62/10
 I will use recycled card for my outer
as it s environmentally friendly
product.
 Easy and less expensive to
manufacture.
8/10 63/10
 I used folding box board for my
outer which contains a recycled
pulp as my chocolate is
environmentally friendly.
8/10 62/10
 I have used a folding box boards
as they contain a recycled pulp
thus making it environmentally
friendly. The material also
protects the product from heat
and moisture during
transportation.
 Aesthetics Development: Logo
Replicating my initial logo in Paint.net
Some of the shapes were made in 2d design and
then imported to Paint.net Improvements to make:
 The alignment of the letters do not flow
with the shape underneath.
 Reconsider- changing the color scheme so
it contrasts well.
 Add a copyright symbol to improve the
The name of my brand
The stream shape replicates
letter C and S
added to the logo. I used
Addition of the leaf and
tree.
Green color was added
to the leaf
aesthetics of the logo and give it a
orange color which was in
my mood board.
professional look.
 Consider removing the tree from the logo
as its already crowded and looks too filled
Development/Improvements up.
 Try to include an image of a leaf and
incorporate it with the rest of the logo.

1. 2. 3. 4.

I started off with my initial design.
I removed the tree on top of the letter S as it made the
logo too crowded which was also one of my
improvements when I did the logo evaluation. Now it looks
more simple and enticing.
I changed the font to Forte as it matches with
curved stream and leaf in the logo thus
contrasts well.
I added a radial gradient on the leaf to make it stand out
from the logo and contrast well with the rest of the logo.
The color of the leaf after the addition of gradient looks
pretty similar to the colors I mentioned in my design
specification.

5. 6. 7. 8.

I tried using clouds effect on the text
and changing the font color to green
but it didn’t contrast very well so I
changed it back to normal.
I changed the font to Segoe Print which
kind of falls in the category of free hand
fonts which fits the rest of the logo very
well. I also changed the font color to
golden which is one of the colors in my
mood board.
I used sea green as my font’s color to
see if it contrasts well with rest of the
logo. It didn’t work out so I removed
it.
I changed my font color back to golden as it was
more contrasting than sea green. I have also
aligned the text to fit along the outline of the leaf
which makes it look properly arranged and
aesthetically pleasing.
9. 10.
On the golden text, I used a sea green radial
gradient to give it a multi tone appearance. As it was
one of the colors mentioned in my design
specification.
13. 14.
I have a added a clipart of a leaf which I
developed using layers and different colors
such a brown. I will try to incorporate this in
my logo.
17. 18.
I added a vignette effect to my leaf to make it
a bit glossy and enticing. It actually worked
out and gave the leaf the very contrast that it
was searching for.
21. 22.
I readjusted the shape of letter S so now it fits
well with the leaf and the rest of the text. I also
paint brushed the upper part of that letter S with
green color as it was black for some reasons.
11.
I reconsidered the sea green radial gradient and
changed it to light yellow linear gradient which fits
with the leaf and contrasts well.
15.
I added a new letter S around the leaf
shape and removed that old stream
shape.
19.
I added a shadow to my text to make it
stand out and more catchy.
23.
I crystallized the text to give it a hazy look
which didn’t really work out and fit with the
rest of the logo as the customers should be
able to read the brand name properly from a
distance, so I removed it.
12.
I gave my logo motion blur to give it a I sharpened my text to make it look
sketchy look and make it stand out. more fine and enticing from far away.
16.
I added a registered trademark symbol on my logo
to improve the general appearance of the logo and
I distorted my logo by adding a bulge make it look professional. As it was one my
effect which creates a smooth texture improvements I mentioned earlier and also in
same as a caramel. design specification.
20.
On the advise of my teacher I changed the font
On the advise of my colleagues, I relocated the to serif and aligned it to the leaf as my product is
trademark symbol and placed it closer to the logo so upper mid-range so I can use serif font. The
that it looks more finer and fits well with the logo. serif font was also mentioned in my design
specification.
24.
I added a slogan as it was one of my
I imported my logo in Photoshop and improvements that I mentioned in my logo
applied the stylize (Wind) effect which development. I also added a gradient on the letter
looked impressive. However, it would make S so it contrasts well with the leaf. Finally, I aligned
it difficult for the customers to read the the slogan with the letter and S and the logo so
brand name. That's why I removed it. that it fits well with the rest of the logo.
 Net Design
Of Outer
In this page of my coursework I will make the net of outer box of my product.
AIMS:
 Make the net using the 2D CAD design software.
 Show development of the initial design.

Box
 Explain advantages and disadvantages of the net in each step and then improve it
in the next one.
 Assemble the net using appropriate tools and techniques.
 The paper that I used to print my net had a thickness of approximately 150 Microns.

During this phase of my coursework, I will try to make the model of my outer that
pretty much replicates the one in the outer box design section. After getting the initial
shape correct I will further enhance the box so that it fits with my design
specification.

Initial Net Design

1. 2.

This is my initial design for the net of my outer box with basic (solid) lines Tuck and tab mechanism to I have sketched the outline of
and simple tabs. I started off with a rectangle in the middle and then added open and close in the initial my frontal cut out and the I added fold lines which give my net a
other rectangles of different sizes on the sides. In the last step I added design. This will be changed to perforation. The design of the professional look and also make it easier to
frontal cut out in the next step. perforation and the finger slot is
simple glue tabs because I was not sure which shape and size of them is subjected to change. fold the net. I will start editing my net to
the most suitable for my box. In the next step I will improve the lines and include a frontal cut out in my next step.
differentiate between solid and folding lines. I will try and add a frontal cut
out as it was one of the features of my box in the Outer Box Design
Section.
Initial net of my frontal cut out design
that was mentioned in the Outer Box
3. Design Section.I added a frontal cut
out and removed tuck and tab from my
net. The frontal cut could be used as a
pop up display once the box is open to
entice customers as it will be used as a
point of sale of display. On the advise
of my teacher I will change the position The pop up display will contain my logo
Frontal cut which will When opened at first the and some sort of design/pattern to
of frontal cut out on my net in the next box will look pretty much attract customers. In the next step I will
act as a pop up
step. Then, it will make it easier to cut display. like above in the picture. create glue tabs that hold the pop up
and assemble the box. display in one place.
 The final model of my

4. 7. packaging. I have added

perforation for my frontal
cut.

I have added a perforation instead of a solid line for my frontal

I have changed the position of frontal cut out on my cut out.This will tear and move up to act like a pop up
For the display
net making it easier to cut and assemble the outer. display.This makes my net look professional as well as making window I glued a
The shape of the tabs is not very suitable and I will it easier to visualize the cut out. Secondly, I also added a piece of plastic
try and change that in the next step. finger slot to make it easier for the customer to open the (polypropylene) on
the back to make it
packaging. In the next step I will change the shape of glue look realistic.
tabs so that they can hold the pop up display In one place.
5. The frontal cut out will
move up and act like a
pop up display.

Finger slot added to

make the product
more accessible for
the customers. Can
be teared to open
the box.

I have changed my tabs as now they have rounded The tab’s shape has
It also makes it easier to cut and been modified so that
edges thus making the outer more ergonomically suitable they hold the pop up
assemble the net as it prevents
for the customer. To let customer see the product inside I the danger of paper cuts. display in one place.
will add a display window in the next step.

6.
I have added a display window on the front side of my
packaging. This adds an additional feature to my packaging as
well as allowing the customer the see the product inside. The
problem with this net is that the type of line used for the fontal
cut out is solid. I will change this to perforation in the next step.
8.
Display window added for better
aesthetics of the packaging. In the
next step I will try to add a plastic
(polypropylene) behind the display
window to make it look realistic.
I changed the shape of top two glue tabs
from rounded to a trapezium. This will be
useful as these tabs will be able to hold the
pop up display in one place after the box
has been opened.
Further
Improvements:
With the help of my teacher I was able to
figure out that the type of line used for
perforation is not suitable and few changes in
the line width, pitch and type could result in
more customer friendly perforation. As they
will be able to tear it more easily now. I will
also add dividers in my next step which will
make it easier to organize the chocolates in
the box. Lastly, when I print my net for my
prototype I must print it on a much more
thicker paper as this time due to the less
thickness of the paper there were quite a few
bends in the packaging. The box was also
not stiff enough.
 Adding Graphics to the net

I imported the net from 2d design into paint.net so
that I could add graphics on it. I set the dpi to 300
to achieve a really high quality in terms of
graphics.
I duplicated the background layer and deleted the
rest of the parts of the canvas so that I could add
colours to different part of the net separately and
when I print the net, the fold lines are visible.
I used orange colour (#ff7733) which was part of my colour Then I tried light blue colour which was part of my
scheme; mentioned in my mood board. However, when I
colour scheme and evident in my mood board.
added the logo to the net the colour of the text CARAMEL However, I decided to take it off as it didn’t contrast
was pretty much the same as the background. So I decided
the logo.
to change the background colour as it would make it difficult
for the customer to read the brand name.

I tried to add a pattern of river surface shining,
with layer mode set to “Glow”, to see if it works.
However, it resulted in being too shiny and
would have made It difficult to add information
on the box.
Finally, I found a perfect colour for my
background as it contrasted well with my logo
and it was more close to the theme of nature
and also linked to the colors in a savanna.
I added a Trapezoid in my pop up display and added a dark
brown (#563119) colour. On the top part of my pop up display I
added a picture of a typical savanna sunset, linking it to my
design specification and my theme of nature. I decided to place
my logo beneath it on the front side of the pop up display to
attract my target audience, when placed on a shelf. I used paint
bucket to fill the trapezoid in the same colour as those of the
trees in the picture so when I add my logo it will create a
contrasting backdrop.
Instead of adding a pattern on the back I just added a
linear gradient comprising of two very light shades of blue
and brown. This move turned out to be simple but
effective. Then, I started adding the information on the
back side of the box. My chocolate is a milk chocolate so I
searched the ingredients of a typical milk chocolate and
placed them here. This is because customer would like to
know which ingredients their chocolate is made of. I used
a simple and legible font so that the ingredients could be
read easily. I also added allergen information

I added a barcode,
recycling symbol,
Mobius loop and a
blank space for the
expiry date.

I tried to make my own nutritional table In Microsoft

publisher. However, when I placed it on my net it
didn’t really blend with the colour scheme of the My teacher pointed
outer box. So, I decided to use a normal nutritional out that the
table found on many packaging's. After a few information needs to
modifications in paint.net I placed it on my be aligned in order for
I used a palm tree leaf to create a pattern on the On the advise of my teacher I decided to add a
packaging. it to look professional.
front side of my packaging. This linked to my pic of a tree similar to the one in the pop up
I made a new layer
theme very well as palm trees are present in a display. I placed it on the top of the side of my
called alignments.
savanna thus connecting to my main theme of packaging. I set the layer mode to glow and also
Where I used straight
nature. I used two leaves of different sizes and decreased the opacity to see if it works. However,
lines to see if my
placed them in an opposite direction to each other. later I decided to place a logo on top and the tree
information and
I set the layer opacity to 100 to create an effect of on the bottom as it would make it look more
symbols were aligned.
leaves fading. professional.
Firstly, when I placed the logo it was too blurry and As mentioned earlier, for both sides I placed the logo on I added the links of my social media pages as a method of
pixelated due to some reasons so with the help of my the top so if my packaging is placed in a way that the side promotion and brand following. I also added the logos of
teacher I figured out a way to sharpen it. On the back side, is facing the front, the customer will still be able to see the relevant social media sites as they would immediately catch
I placed the logo on the top right corner as I found that in brand name. For the tree, I placed it on the bottom with customer’s eye.
many example packaging's that I looked at. I also added a layer mode set to normal. However, I did darken the colour
nutritional table which this time blended with the to make it stand out. Logo: I placed the logo four
background. times on my packaging with
the biggest one being on the
Product Description: I front.
added a description of what
the product is like on the top. I Storage Instructions: to
used an italicized serif font let the customer or retailer
thus attracting customers. know how to store the
product, in order to retain
its high quality.
Address: So If customers
Symbols:
have any complains they
I added all the relevant
can access the company via
symbols with all of
their email or their address.
them being black and
white.
Batch number: I also added batch
Best before date: I made a rectangle
number on the side of the barcode
for date of production and expiry date
I continued with my pattern and theme of trees in the to make my packaging more
as in most of the chocolate
packaging and placed a single tree on the bottom left side. professional and also make it easier
packaging's I looked at, this technique
But this time I decreased the opacity of layer to make the for customers to give a reference of
was the most used as the expiry date
tree a bit lighter and blend it with the background. This the product for complains. QR Code: I also added a QR is subjected to change. In this
effect allowed the text to be legible as well as the tree code which our customers can scenario leaving a blank space is the
being visible. scan and get a special discount. best option.

Further
Improvement:

Lastly, I placed my sharpened logo on the pop up display to entice
the customers. Also fulfilling the requirement of my design
specification that the logo will cover 40-60% of the front side. On
the bottom left corner I placed the net weight and number of bars
in this packaging. I placed this information specifically here as its
one of the information that is placed on the front side of the
packaging. On the finger slot I wrote OPEN HERE! to let the
customers know how to open the packaging‘ as well as attracting
the customer.
After seeing some sample packaging's I noticed that the
bottom side of the box is mostly white so I decided to
implement that in my packaging. In the end I also placed
CMYK bars on the advise of my friend.
If I had a chance to
improve my graphics on
the net I would’ve created
a much better pattern for
the front side of the
packaging. I would’ve
changed the position of
In the final step, I reconsidered the tree pattern and felt that it some of the information on
was too repetitive and boring so I decided to take it off and this the back.
time I changed the size of every second leaf that I placed and
later changed their opacity to 150 in some leaves and 210 in
others. On the advise of my teacher I also changed the font of
net weight on the front to a more legible font making it easier for
the customer to read. I also changed the colour of the
trademark symbol on my logo to white as it contrasted the
background well. Lastly, I changed the position of CMYK bars.
 Adding graphics to the Wrapper net

After I had exported my net into Paint.net. I Then, I started to add all the required For the front side of the wrapper I tried
I created the net of my wrapper in 2D Design.
started to add background colours. I added information on the back. I placed my logo adding a silhouette of the ‘S shaped leaf’
Considering, that my bar is a family bar, I
a linear gradient on the back side of my on the top. I also added a barcode, form my logo. I changed the opacity of the
decided to create a wrapper with perforation for
wrapper. estimated net weight and allergen layer and set the layer mode to glow. I also
opening. This provides an easier access for the
statement. placed my logo in the middle. However, all of
customer. I took some basic measurements from
this didn’t contrast well so I decided to
my block model for the wrapper.
remove it.

On the advise of my
teacher, I placed my
logo in the middle with
a savanna tree on the
bottom. I also added
the net weight on the
front of the wrapper.

I also added the

I added a Reference
On the bottom of the front side of my wrapper I placed a energy intake icon on
silhouette of a tree from my surface design on outer box. As the front side of the
this part of the bar was to be shown from the display window, I wrapper. This will
placed the tree in a way so when all the bars are stacked it will provide customer with a
create a backdrop of savanna. This feature will be visible from summary of the
nutritional values of the
the display window thus enticing customers.
bar.
Assembling the wrapper
QR code so that
customer can scan
it and avail an offer.
Litter man,
recycling symbols
were also added.
I made a rectangle on the side of the bar and added
On the bottom of my wrapper
the flavor of the bar with the fillings used. I added the storage
instructions as well as the
best before date.

I printed the net of my wrapper
on an A4 piece of Solid White
Card. I cut the net using a
cutting mat, safety rule and a
cutter.
I glued the wrapper using contact glue. However, After sanding the block model to the
After wrapping the block model
when I placed the block model in the wrapper it turnedrequired size, I cut a piece of This time it was a perfect fit as
in aluminum foil, I placed it in
out to be bit bigger than intended. I think it happened aluminum foil to wrap my chocolate the block model perfectly fit the
the wrapper to see if it fits.
due to improper scaling of the net when printing it. Butmodel. This was mentioned in my wrapper.
I was able to fix this problem by sanding the block design specification as aluminum foil
model to fit the wrapper. preserves the chocolate.
 Materials Development: Making a block model
To make a model of my chocolate bar, I will be using three materials/processes available at our school lab. This includes
Styrofoam, Basal Wood and Laser Cutting. I must make sure that my bar is thin and tall in order to fit my outer box. It must
also have segments which will make it easier for people to eat it as its a family bar and supposed to be shared.

1.

I started with the material Styrofoam. I cut it in a

shape of a cuboid using the hot wire cutter. It’s
a device with a nichrome or stainless steel wire,
which is heated via electrical resistance at
approximately 200°C. As the wire is passed
through the material to be cut, the heat from the
wire vaporises the material just in advance of
contact.
Using a pencil I marked the initial lengths
of my bar on the Styrofoam. Then, I tried to
cut it as closely to the marked lines using a
hot wire cutter.
I used the sand paper to remove the
access Styrofoam on all sides. This
left a lot of Styrofoam dust. I also
found that it was quite hard to keep
the sides even while rubbing them
on the sand paper.
I angled the top and bottom
corner of my bar to give it a
smooth edge on the corner. It
was quite difficult to get the
curve of the same size on both
sides using the sand paper.

2.

As it’s a Family Chocolate Bar I decided to have

segments on my bar which will make it easier for
people to share the chocolate. It will also make it I took a block of Basal Wood and
easier to eat as the bar is quite tall. So, after marked the outline of my bar with a
some calculations I marked them with a pencil. pencil. Initially, I tried to cut it as
closely as to the marked lines so
that I would have to sand it less.
At first, I used sand paper to smoothen
the sides of the Basal Wood and shape
it to the required dimensions. This left
wooden dust as well, but it provided a
much smoother finish as compared to
Styrofoam. However, I struggled to
keep the sides even while using sand
paper.

I used the Band Sander instead of sand paper which
provided me a much smoother and even finish for the
sides of the Balsa Wood as compared to the sand
paper. However, one negative of using the band
Sander was that it produced a lot of wooden dust so
as a safety precaution we had to wear goggles.
As my bar had a more complex shape than
3. others, my teacher suggested me not to use
casting powder. Thus, I used laser printing to
make the third model of my chocolate bar.
Firstly, I made the basic shape of my bar
on 2D design using several tools. I had
some difficulty making the curves initially.
But after taking some measurements
from my previous model I was able to do
it correctly. I also figured out the width of
the bar and how many pieces of laser cut
wood I am supposed to have.
I angled the top and bottom corner of my
bar to give it a smooth edge on the
corner. But this time I cut a small piece
of sand paper to curve the sides. This
allowed me to have a more smooth
curve and it was pretty much the same
size on both sides.
I had to remove some of the pieces
as I got the measurement for the
thickness of my bar slightly wrong.
As I got the measurements of my bar correct I
didn’t need to use a sand paper. Thus, I
started to stick the different pieces so that they
make up a bar. For this I used PVA glue and
applied it on the wood using a spatula.
I used a clamp to apply pressure to my
chocolate model, after I had finished
sticking the pieces together. This
allowed them to join properly and not
come off after some time.
I marked the segments on my bar, as
it’s a Family Chocolate Bar and it’s
supposed to be shared.
Using the Razor Saw, I cut the
segments. However, this time the V-
shaped segments were more accurate
and both of the V-shape had a
consistent angle. Whereas, with
Styrofoam the V-shaped segments were
not accurate and there were some
inaccuracies.
From the three materials I
tested for my chocolate
bar’s model, they were all
found to be of the same
dimensions.
In the final step I painted all
three chocolate models so that
they resemble a chocolate. In
terms of drying and difficulty
level, Styrofoam turned out to
be the most difficult as it took
longer to dry. Whereas, the
paint took the least time to dry
on wood and it also had a
smooth finish.
 Materials Testing and Development- Conclusion
Criteria Styrofoam
Using the hot wire cutter allowed me to cut
Was it easy to shape? the Styrofoam in desired shape. However,
sanding the sides to make them even wasn’t
easy and required a lot of effort.
7/10
Balsa Wood Laser Cutting
This was the most difficult, among the three
materials, to cut. Bench hook did provide
The process was automated so I didn’t have to
shape anything. However, it wasn’t easy to create
some stability while cutting. However, grains the outline of the shape in 2D Design.
of wood made it really hard to sand . But 9/10
using Band Sander made it easy to shape.
8/10

How quick was it to It took the longest among the other three
materials, particularly because it was the first
It was relatively quick as now I had all the
measurements. The use of Band Sander also
Creating the outline on 2D Design didn’t take
a lot of time. However, the laser cutter did
create ? model and I wasn’t quite sure about the
measurements. Secondly, sanding also took
made the model quick to create.
9/10
take a fair amount of time thus making the
process not as quick as making the model
quite a lot of time. out of Balsa wood.
6/10 8/10

How smooth was its
surface finish?
Was the process
short/long,
easy/hard?
The surface finish of the model made out of
Styrofoam was very rough and it required
thorough painting.
7/10
The process was quite long and hard as the
sand paper was difficult to use and hot wire
cutter didn’t provide an even finish.
7/10
The surface finish was much better than
Styrofoam and required less paint.
It had the best surface finish in comparison to
the other two. It was hard and didn’t have
The smooth finish made it easier to add
segments.
any grains thus suitable for painting.
9/10
8/10
The process was quite short and easy The process was the shortest as making an
Due to the use of Band Sander which made outline didn’t take much time. Overall, The
the process quite quick.
10/10
process was easy as joining the sides didn’t
take much time however it did take some
time to dry.
9/10

The bar wasn’t accurate as it was difficult to The bar was accurate as to make the sides This model was the most accurate as it was
How accurate was the shape. The sides were uneven due to the even, I used Band sander. Surprisingly, automated. It did take some time to get the
model? improper use of sand paper.
7/10
making the segments turned out to be easier.
Use of chisel on wood allowed for almost
measurements right in 2D Design. However,
the outcome was accurate with all the sides
perfect segments. even. The amount of curvature was also the
9/10 same on both ends of the bar.
9/10

Overall Rating 34/50 44/50 44/50

Considering that Balsa Wood and Laser Cutting had the joint highest rating. I
decided to chose the model made out from Balsa Wood. This is because the
model looks more realistic as compared to Laser cutting even though it was more
accurate. In the beginning, I found it difficult to sand the wood using 120grit sand
paper. However, on the advise of my teacher I used the Band Sander to even the
sides which provided me with a much smoother and consistent finish on all sides.
Making the model out of Balsa Wood was less time consuming unlike Styrofoam.
Outer Box

• Make an outline of an initial net using dimensions from design specification and final design.
• Print the net to see if the measurements work (go back).
• Make amendments to the net’s dimensions or opening/closing mechanisms after testing initial net.
• Export the file from 2d design format to a png file. Set the dpi to 200.
• Use the full scale net to add your graphics in paint.net.
• Start adding graphics and necessary information required on an outer from the design specification
and final design.
• Is the font and text size used for the information legible?( go back).
• Add all the legal information and logos.
• Print the net using an A3 inkjet printer on high resolution( delay 15 min)
• Check the print quality to ensure that the colours corresponds to design on screen
• Using the cutting mat and safety rule cut the net precisely around the corners. ( if not print again).
• Use the scoring method using the blunt end of the knife to fold your net accurately.
• Take an acetate sheet and mark it slightly bigger than the original display window
• Cut the marked acetate with the display window’s shape. ( If any inaccuracies go back).
• Glue the cut acetate piece using a craft glue.
• Use contact adhesive to stick the sides and join glue tabs.
 Outer box
Manufacturing Plan: Flow Chart Wrapper
Chocolate block model
Add the
graphics and
START No Are there
inaccuracies
Yes
Glue the cut
acetate piece
net
Are all the
requireme
requirements
in the display using a craft nts met?
from the
window? glue. outer.
On 2D design,
Use contact Save the net
make an outline
Cut the marked adhesive to Import the with flattened
of the initial net.
acetate with stick the sides outline to layers as a
the display and join glue Paint.net. ‘JPEG’ image.
window’s tabs.
shape. Change the
Take a block of
Yes
Print the net to scale of the
Balsa wood Does the net by
see if the Take an acetate and trace your wrapper importing the
measurements sheet and mark No
bar’s cover the image into 2D
work. Alter the it slightly Make
dimensions. bar fully? Design.
measure bigger than the appropriate
ments and original display changes
check line window. Cut the access
wood using a Print the Rescale the Are all the
types.
Using the Tenon saw on wrapper to net or alter dimension
ruler, are all Bench hook. see if it the s the
measureme covers the dimensions. same? No
Score the fold
nts correct? No bar. Yes
lines using Smoothen the
blunt end of sides of the Print the net
Yes the knife. block using a
Make an
outline of your on a normal
120 grit sand card.
Import the net to wrapper’s net
Using the paper.
Paint.net, on 200- on 2D Design. Change
cutting mat Wait for ink
dpi the text
and safety rule to dry
cut the net size or
Ask your Are the Measure the font.
Add all the peers if precisely required
around the dimensions of Is all the
graphics, logo, they can dimensions the bar
corners. text and
legal information read the No achieved?
information
and relevant informatio No
Yes Yes legible?
symbols. n from a
distance.
Yes
Do the Using the
colours on No razor saw, cut
Yes To Assemble, cut
outer and the 45 degree
Is the font the wrapper using
screen Is the
size angles needed cutting mat and
correspond model
legible? No for the safety ruler and
? fully
segments.
painted?
No then join the glue
Yes tabs using
Print the net Adjust printer Paint the contact adhesive.
Export the net using an A3 colour chocolate
with flattened inkjet printer Wait for the Wait for glue
management model with
layers as ‘JPEG’ set on high paint to dry. to dry.
settings before brown Acrylic
image. quality (at 600 printing again. paint.
dpi).
FINISH
 Flow Chart
Add the

START No Are there

inaccuracies Yes
Glue the cut
acetate piece
graphics and
net
Are all the
requireme
requirements
in the display using a craft nts met?
from the
window? glue. outer.
On 2D design,
Use contact Save the net
make an outline Cut the marked adhesive to Import the with flattened
of the initial net. acetate with stick the sides outline to layers as a
the display and join glue Paint.net. ‘JPEG’ image.
window’s tabs.
shape. Change the
Take a block of scale of the
Print the net to
Take an acetate Balsa wood Does the net by
see if the
sheet and mark and trace your wrapper importing the
measurements
it slightly bar’s cover the image into 2D Make
work. Alter the
bigger than the dimensions. bar fully? Design. appropria
measure
original display te
ments and
window. changes
check line Cut the access Print the Rescale the Are all the
types. wood using a
Using the wrapper to net or alter dimension
ruler, are all Tenon saw on see if it
Score the fold the s the
measureme Bench hook. covers the dimensions. same? No
lines using
nts correct? No blunt end of bar. Yes
Smoothen the
the knife.
sides of the Print the net
Yes Make an
block using a outline of your on a normal
Add the graphics
120 grit sand wrapper’s net card.
and necessary Using the paper. on 2D Design.
information on cutting mat and Change
the net. in the text Wait for ink
safety rule cut
Paint.net size or to dry
the net precisely
around the Are the Measure the font.
Ask your
corners. required dimensions of
peers if Is all the
Add all the legal dimensions the bar
they can text and
information and read the Yes No achieved?
information
relevant symbols. informatio legible?
n from a Do the Yes
distance. colours on Using the
No Yes To Assemble, cut
outer and razor saw, cut the wrapper using
Is the font screen the 45 degree cutting mat and
Is the
size correspond angles needed safety ruler and
model
legible? No ? for the then join the glue
fully
segments.
painted?
No tabs using
Yes contact adhesive.
Print the net Adjust printer Paint the
Export the net colour chocolate Wait for glue to
using an A3 Wait for the
with flattened management model with dry.
inkjet printer set paint to dry.
layers as ‘JPEG’ settings before brown Acrylic
on high quality
image. printing again. paint.
(at 600 dpi).
FINISH
 Cumulative Gantt Chart
Hours
9
Number of Hours

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et st rk
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a
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C p o d r u r k a M A
A a C a P
Ex M M

Hours

Tools/Equipment
Computer- to design logos, net for
wrapper and outer
Hot Wire Cutter- to cut through
materials such as Styrofoam
Tenon Saw- to cut through materials
such as Balsa wood
Laser Cutter-
Sand Paper- to smoothen surfaces
of materials such as Styrofoam and
Balsa Wood
Cutting Knife- used to cut and
score outer and wrapper nets
Band Sander-
Razor Saw- to shape my bar and make
segments.
Tools and Safety
Risks Precaution Materials Use
Not sitting up straight in your chair (i.e. Take frequent brakes to avoid over use of Styrofoam Styrofoam is used to
incorrect posture) can lead to back and computer. Move your limbs and stretch after create an accurate
neck ache which prevents you from using the computer for long time. Avoid sitting prototype of the bar
sleeping properly. Typing at high speeds in an uncomfortable position and always
for long periods without a break can lead adjust the seat appropriately. Consider due to its versatility. Its
to RSI causing swelling of the wrist or lowering the screen brightness to prevent eye also used to create
finger joints. If connected to mains, may strain and head aches. outers.
cause an electric shock or trip over wire.
Balsa Wood Balsa wood is a soft
Leaving the Hot Wire Cutter on for too long Do not apply pressure to Hot Wire, as the hardwood used to
will overheat it and can potentially cause a wire may snap. Turn it off as soon as you create a block model of
fire. It can severely burn hands. If finish your work. Avoid distractions when
Styrofoam is left close to the wire for too using a Hot Wire Cutter and don’t rush
the chocolate bar.
long it can release smoke. your work as you might ruin it. Never
inhale the smoke produced.
Solid White Card- The solid white card is
120 gsm used to print out the
Tenon can lead to an injury if used at a When using a Tenon Saw always use it on outer and the wrapper.
high speed as mistakes can occur. Its is a Bench Hook which provides stability 1 x A4 The outer was printed
also very sharp and cause cuts and while cutting wood. This prevents the user 1 x A3 on an A3 sheet while
bleeding. Cutting wood with Tenon could from getting cuts. Wear goggles to avoid the wrapper was
be harmful for your eyes due to flying splinters and keep your hands away from
splinters. the cutting path. printed on an A2 sheet.
Don’t leave the laser cutter unattended. Acrylic Paint Acrylic paint was used
Insure that the extraction unit is turned on to give a smooth
before operating and use only when surface finish and make
supervised by a teacher. the block models
Rubbing Sand Paper constantly can result When using the Sand Paper, don’t use it too closely resemble a
in dust entering user’s eyes and causing close to the skin. Wear gloves or a face mask chocolate.
pain. Its also harmful as it can be inhaled. to prevent the inhalation of the debris.
If rubbed at fast speed, can produce an Always use it with a firm grip and avoid PVA glue PVA glue is used to
irritating sound which could distract others. applying too much pressure which may attach the several
Using Sand Paper for longer periods could deteriorate the shape of bar. pieces of laser cut
lead to the skin of the hand being wood together.
damaged.
Cutting Knife is very sharp and can cause Use the cutting knife with the secure lock on
Craft glue Craft glue is applied to
assemble the outer box
cuts and bleeding. If used against a to prevent it form slipping. Keep the extended
normal ruler or the secure lock isn’t used, blade short and always use it with firm grip. and wrapper. It was
it can slip over and cut your finger. applied on the glue
tabs.
Razor Saw has sharp edges which can The user must handle it with care when not in
Aluminium Foil The block model is
wrapped in aluminium
lead to cuts. Due to weak grip Chisel my use to avoid injuring others. They must use the
slip, ruining the shape or damaging razor saw away from them, with a steady grip, foil to preserve it.
property. Flying debris can enter eyes or to prevent the risk of cutting themselves. Wear Aluminium foil retains
inhaled which could be damaging. User goggles and face masks to avoid the debris heat thus prevents the
may use it towards them thus injuring from causing irritation. chocolate form melting.
themselves.
Acetate Acetate is a transparent
thermoplastic, used to
create a display
window on the outer
box.
 Public Survey
1). Does the surface design correspond to my target market? 6). Can you suggest any improvements.

Yes

No

2). How well is the outer box constructed? 7). Is the shape of my bar convenient?

Excellent Satisfactory Yes

Good Bad No

3). Is the text legible? 8). Is the wrapper of my bar easy to open?

Yes Yes

No No

4). At what price would you buy this product? 9). What is it that you like most about the product?

1-2 QR 5-6 QR Aesthetics Price Positioning

3-4 QR 7-8 QR Construction Material

5). Does my outer appeal to young adults as intended? 10). What other product in the market would you pitch It
against?
Yes
Cadbury Lindt
No
Mars Toblerone
 Public Survey Results
1). Does the surface design correspond to my 2). How well is the outer box constructed? 3). Is the text legible? 4). At what price would you buy this product?
target market?
8 4.5
7 4
6 3.5
3
2 3
5
2.5
6 4 2
3 6 1.5
2 1
Yes No 1 0.5
0 0
Excellent Good Satisfactory Bad Yes No 1-2 QR 3-4 QR 5-6 QR 7-8 QR
The results show that the surface design According to the people’s response, my box was well Most people thought that the text used People chose between 3-4 QR as the price of
corresponds to my target market thus enticing my constructed with the inclusion of a display window. and font for the information is easy to my chocolate. This is because my product is
intended target market. However, some people pointed out some minor errors read. This is because I used a sans-serif mid-range.
in gluing the tabs. font which was mentioned I design
specification.

5). Does my outer appeal to young adults as

6). Can you suggest any improvements. 7). Is the shape of my bar 8). Is the wrapper of my bar easy to open?
intended? customer friendly?

People suggested to change the pattern used on 3

the front. They also suggested to change the 3
4 4 background colour slightly so that t fits the surface 5
5
design used o top.

Yes No Yes No
Yes withNo
Many people agreed my use of surface design to The shape of my bar according to most people I The results show that the wrapper is easy to
appeal to young adults. However, others disagreed and asked is not suitable and the width is a bit too off. open according to most people. This is
thought that it doesn’t appeal to the intended target However, in my opinion it’s a family bar and its because I have included a perforation thus
market due to its background colour. supposed to be shared. providing an easier access for the customers.

What is it that you like most about the product? What other product in the market would you pitch
9). 10). It against?

3.5 4.5
3 The majority of the people 4 Many people chose
liked the aesthetics of my 3.5 toblerone because it has a
2.5 outer particularly the similar theme, as mine, of
3
surface design on the top. nature. They also chose it
2 2.5
Some people also liked because the shape of my
1.5 the way my box 2 bar is also quite complex
assembled and 1.5 and unique, similar to
1 constructed. However, 1 toblerone’s. No one chose
0.5 they did point out some 0.5 mars as it appeals to a
minor gluing errors. 0 totally different market
0 Cadbury Mars Lindt Toblerone than mine.
Aesthetics Price Costruction Material
Positioning
 Evaluation Against Specification

Proposed modifications

Explain
Why
Add ratings School facilities
Based on my ratings I
have achieved 85%

Not able to meet the

size of my box
Due to the printer at
school

Solid White card 120 gsm

Wrapper Evaluation ( with screen shots)
Health and Safety
Materials page (all the materials used)
Fix the Specification
Do Evaluation against the specification.
Fix the Survey ( Add Photos )
Modifications page.
• Product Comparison

Orthographic Drawing
Wrapper Drawing