Packaging and Merchandising Design Exercise 2 - Structural Anatomy of the Money Packet

4th May 2026 (Week 3)  -  23rd May 2026 (Week 5)

Insha Thahirah Rajab - 0360671

Design Principles - Section 02

Bachelor's Degree  in Creative Media (Honors) - Taylors University

Exercise 2 - Structural Anatomy of the Money Packet

*

CONTENTS

Lectures

Instructions

Exercises

References

Feedback

Reflection

*

LECTURES

Week 3

Architecture of the Fold

Figure 1.0 What is Packaging (PDF), Week 2(27/04/2026)

This lecture briefed us an understanding of what packaging is, its function, aesthetic and purpose. We learnt the hierarchy of information, placement. We also touched on the types of folds we would be using for our assignments: The Mountain, and Valley Folds, and well as the mechanics of closure: Friction Fits, Interlocking tabs, Tension locks, and the Click Factor. Finally, we look at the UX of paper and the handoff of the final product.

*

INSTRUCTIONS

Figure 1.0 Module Information Booklet (PDF)

*

EXERCISES

Exercise 2 - Structural Anatomy of the Money Packet

1. Project Overview

In this exercise, we are stripping away the surface graphics to focus on the architecture of paper. Your goal is to reinvent the money packet through structural innovation. You will explore how a single sheet of paper can be transformed into a functional, secure, and aesthetically pleasing container through folding, interlocking, and die-cutting.

2. The Challenge: "The White-Out Project"

Design a series of two (2) structurally unique money packets using only white, unprinted cardstock. Because there is no visual design to rely on, the "beauty" of the packet must come from:

• The logic of the fold.
• The ingenuity of the closing mechanism (no glue or tape allowed for the final closure).

3. Structural Objectives

• Kinetic Experience: How does the packet move when opened? Does it expand, slide, or "bloom"
• Glueless Integrity: At least one of your designs must use an interlocking tab system that remains secure without the use of adhesives.
• Materiality: Utilize the weight and grain of the paper to provide structural strength.

4. Technical Constraints

• Color Palette: Strictly white (different shades/textures of white or any color paper are permitted).
• Dimensions: Must comfortably hold a standard banknote. You are encouraged to experiment with orientation (vertical, horizontal, or diagonal).
• Quantity: Two distinct structural variations (e.g., one origami-inspired, one industrial/geometric, and one experimental)

5. Suggested Areas of Exploration

• The Pop-Up: A structure that lifts the banknote toward the recipient when opened.
• The Multi-Stage Fold: A packet that requires multiple "unfold" steps to reach the money, building anticipation.
• The Tension Lock: Using the natural tension of curved paper to keep the packet closed.
• The Asymmetrical Closure: Moving away from the standard rectangular flap to something organic or geometric.

6. Deliverables

• A set of two technical die-lines (1:1 scale) indicating cut lines, mountain folds, and valley folds.
• Two high-fidelity mockups using 160gsm–220gsm any color specialty paper.
• A 10-second video for each packet demonstrating the opening and closing movement.
• E-portfolio to show your process.

*

WEEK 3

We had a very interactive session. We went through the slides of understanding the different types of folds and how to do so, as well as observing physical money packet packaging to try to make our own. In class, we cut open and created a simple draft design of the money packet, to understand its structure, sizing, and interlocking systems used. 

FIRST ATTEMPTS

These were my first few designs I did for the money packet. I focused more on an origami-like approach and used one entire sheet of A4 paper instead of having a variety of cuts and folds. 

Attempt 1

This was my first concept: 

Figure 1.2 Concept 1 Envelope, Week 3(09/05/2026)

This followed an envelope style folding, using different paper types and thickness to understand the folding. The design was simple yet effective, I used a banknote inside to understand the sizing dimensions.

This is a video demonstration: 

Figure 1.3 Concept 1 Envelope with money, Week 3(09/05/2026)

Attempt 2

This was my second concept:

Figure 1.4 Concept 2 Envelope, Week 3(09/05/2026)

I used 3 different types of paper thicknesses for experimentation, and the design included 3 different ways to hold money: inside, in the middle, and on the outside sleeve.

Figure 1.5 Concept 2 , different variations of Money in Packet, Week 3(09/05/2026)

These were the die-lines I drafted out to gain an understanding on the difference between mountain and valley folds. When folding a single sheet of paper into a packet, without using any types of locking, cutting or closing system, it feels flat and one dimensional.

Figure 1.6 Concept 2  Die-Lines, Week 3(09/05/2026)

This is my final outcome and video demonstration:

Figure 1.7 Concept 2  Money Packet, Week 3(09/05/2026)

Figure 1.8 Concept 2  Money Packet Video Demonstration with Money, Week 3(09/05/2026)

Simultaneously, I worked on some other folding styles to understand their functions and how money can be stored. These weren't used in my final outcome:

Figure 1.9 Concept 2  Other Variation Packets, Week 4(12/05/2026)

WEEK 4

Week 4 class was cancelled, so we had to work on our sketches and folds in class. We were expected to come up 10 sketches, try out some folding, and show our work to sir. Using the lecture notes, we had to implement the different type of folds (mountain fold, valley fold), and include a die-cut diagram and sketches to be presented. Our final design had to be based on one of our sketches, and a video mockup should be filmed and posted. I sent sir some of my early folding works and he told me to bring to class for feedback.

WEEK 5

During week 5 I showed sir my packages and got the necessary feedback. I hadn't done sketches, so I went home and worked on that first thing. The assignment was due this week, and due to my early works being rejected, I was somewhat behind as I had to come up with new ideas, mock-ups and then eventually die-line and fold. I decided to take inspiration from both references and my own concepts and sketch them down, later including measurements as I worked with mock-up versions.

SKETCHES

During week 5, I consulted with sir and understood the true intention behind this exercise, to understand the mechanics of packaging a product, such as money. This includes using paper in a mechanism that involves more technical folding, cutting and a closing mechanism specifically, keeping the money safe. In addition, making the design recognizable and unique scored points, as taking inspiration cannot be used for the final outcome. We had to make our die-lines using illustrator rather than hand-drawn, for a more professional and accurate sizing measurements.

I went back home and produced some ideas, merging some from references. These were the 10 sketches I came up with, some stronger than others:

Figure 2.0 Sketches #1, Week 5(16/05/2026)

Figure 2.1 Sketches #2, Week 5(16/05/2026)

Figure 2.2 Sketches #3, Week 5(16/05/2026)

Figure 2.3 Sketches #4, Week 5(16/05/2026)

 Sir suggested I proceed with sketches 1 & 2. I did many many trial and errors for the exact measurements, also getting a feel for what quality paper works, and how each mechanism would function.

Afterwards, I decided to update my original sketches and keep folding until I get my desired outcome.

PACKETS PROCESS

Packet 1

I used a variety of different paper types, sizing and folds to get the desired result from my sketches. I had started with bigger sizes, but after taking note of the size of a banknote, I was able to get the perfect measurements, in a way that changed the system I designed.

Figure 2.4 Packet 1 Mock-ups, Week 5(19/05/2026)

This is a video demonstration of my first concept on A3 paper:

Figure 2.5 Packet 1 Mock-up Video Demonstration, Week 5(19/05/2026)

The heart cutout didn't make sense to me, as It did not reveal or show the money in this packet. Moreover the locking mechanism made sense without the need for any sort of bondage, or gluing. I decided to sketch the new concept in mind.

Figure 2.6 Packet 1 Updated Sketch, Week 5(19/05/2026)

I moved onto thicker paper next, these were all my versions together:

Figure 2.7 All Packet 1 Mock-ups, Week 5(19/05/2026)

This was a recorded demonstration of the final packet concept using A3 200 gsm art paper. This served as the final template draft:

Figure 2.8 Packet 1 Mock-up Video Demonstration, Week 5(19/05/2026)

Afterwards, I decided to import these dimensions onto Illustrator and create the die-lines before sending over for printing. It was my first time creating die-lines for a package, so I watched a few tutorials and did a lot of trial and error, especially for the more complicated curves.

Figure 2.9 Making Packet 1 Die-Lines on Illustrator, Week 5(21/05/2026)

I duplicated most of the detail curves and only drew out one half of the top and side flaps. I did a portrait orientation version as well, added labels and the die line was ready for submission, and to print.

Figure 3.0 Packet 1 Die-Lines on Illustrator, Week 5(21/05/2026)

Figure 3.0 Packet 1 Die-Lines on Illustrator (Portrait), Week 5(21/05/2026)

 

Packet 2

For packet 2, this proved to be a more complicated and geometric design, so a huge process was gone through before getting the perfect outcome. 

The inside function as easy to understand from the start, so I started off my studying the outside interlocking mechanism before focusing on the shape.

Figure 3.1 Learning locking mechanism, Week 5(21/05/2026)

This was a video demonstration of my understanding:

Figure 3.2 Learning locking mechanism Video Demonstration, Week 5(21/05/2026)

I cut out my very own star and stuck it to this lock to grasp the geometric shape being in place of this lock.

Figure 3.3 Adding Star shape to locking mechanism, Week 5(21/05/2026)

Next, I opened the packet and traced its outlines to study the mechanisms and measurements of this packet.

Figure 3.4 Tracing Packet 2 Shape, Week 5(21/05/2026)

I then made a huge number of mock-ups, trying to perfect this design I had in mind.

Figure 3.5 Traced Packet 2 Mock-up, Week 5(21/05/2026)

This is a video demonstration of my concept:

Figure 3.6 Packet 2 Mock-up Video Demonstration, Week 5(21/05/2026)

Here is a compilation of all my revisions:

Figure 3.7 All Packet 2 Mock-ups, Week 5(21/05/2026)

I also studied the placement and design of the star. I updated this, along with the sketches in my notebook, with new revised measurements.

Figure 3.8 Packet 2 Updated Star and Sketch, Week 5(22/05/2026)

After finally getting a mock-up I was happy with, I imported it onto illustrator to create the die-lines.

Figure 3.9 Creating Die-Lines for Packet 2 on Illustrator, Week 5(22/05/2026)

I used a star shape tool to get an accurate star shape, once I was done, it was ready to be printed.

Figure 4.0 Final Die-Lines for Packet 2 on Illustrator, Week 5(22/05/2026)

PRINTED MOCK-UPS AND REWORKS

I visited Archprint to print on A3 paper. I selected their 230gsm art card which was suitable for packaging, was smooth and sturdy, but easy to cut and fold. These were my first printing attempts.

For Packet 1 I found that everything was perfect aside from the top line, it needed to be moved up by a few inches to perfectly fold.

Figure 4.1 Packet 1 Printed Mockup First Attempt, Week 5(22/05/2026)

I updated the die-lines on illustrator and reprinted again. The outcome was perfect for submission.

Figure 4.2 Packet 1 Updated Die Line, Week 5(22/05/2026)

For the second packet, there were a few issues. Firstly the interlocking tab needed the slit to be longer.

Figure 4.3 Packet 2 Printed Mockup First Attempt, Week 5(22/05/2026)

Then the star folding mechanism wasn't as smooth as I would've liked. It didn't feel aligned. I played around with some printed mockups for a bit, understanding its shape and cutting around. 

Figure 4.4 Packet 3 Printed Mockups Reworking, Week 5(22/05/2026)

I decided I wanted to corners to be sharper and the star to feel more like a star. I then took a picture and retraced on illustrator, making sure to note down its measurements.

Figure 4.5 Packet 2 Updated Die Line, Week 5(22/05/2026)

It was finally ready for the last printing.

FINAL OUTCOME

These are what my two money packets looked like side by side. They were functional and served an aesthetic. I was happy with them.

Packet 1

This is the final Packet 1 design:

This is a PDF of the die-lines

This is a video demonstration with money:

Packet 2

This is the final Packet 2 design:

I ended up preferring the vertical layout more. The opening felt more intuitive and interesting, and the star design aligned better. It looked more professional.

This is a PDF of the die-lines:

This is a video demonstration with money:

*

FEEDBACK

Week 3

Specific Feedback: Go home and try to use your own money as a sample size, create a system that is unique and requires little to no glue. 

General Feedback: Experiment with different sizing and use different papers to understand the difference in folding and final quality. Make sure your system is unique and make sure to document each step on the e-portfolio Use the money packet in class for sizing reference and dimensions. 

Week 4

Specific Feedback: Can I see how the first design works? I think this version is easier to open and close. Can you show it to me tomorrow? Since I've canceled the class today. Still have time. The deadline is next week.

General Feedback: Sorry to informed you that class will be cancel today as I need to attend a one day training in KL. Kindly update your progress for the exercise 2 in the comment section. Make sure you have enough sketches (at least 10 ideas) to show. Label all the sketches for me to provide feedback later. 

Week 5

Specific Feedback: Your design needs to be more original and something you came up with. I have seen your designs in another student's work, and want everyone's designs to be unique to one another. Try to sketch some out (even 3 is enough), change at least one part to make it an original design. Even the ones you have already made, keep them for documentation on the e-portfolio, however try to tweak them up a bit to see what other variations you can make. Look at your classmate's concepts and their sketches, see how they come up with their very own folding styles based on many different ideas. Try to show me this first.

General Feedback: Make sure I have approved your sketches before you move forward with folding and creating die-lines. Your envelopes have to be different from ones online and follow the guidelines we learnt in class for the folding.

*

REFLECTION

Experience: Although a very tedious and time-consuming exercise, exercise 2 really made me understand the physical aspects of packaging design. Hands-on work taught me a lot on how opening and closing a package works, how thought and intuition goes into it. I learnt how to create die-lines on illustrator for the first time, and use measurements to get accurate sizing.

Observations: Opening up an existing money packet, measuring its dimensions and understanding its folding mechanism helped me grasp how packets work, how each flap can be glued or interlocked down to create an opening. I observed the different sizes of money and how a packet should cater to all. By looking at my classmates work, I was able to understand how to do sketches and create my own die-lines for both packets.

Findings: Through my findings, I learnt different folding styles, how paper can be manipulated in ways to create flaps, openings, and interlocking systems, even without glue. I watched tutorials on creating die-lines on illustrator. and I found myself making updates through test printing, and trial and error mock-ups.