foldable cardboard product design

Project Description
We are looking for an experienced Product Designer / Packaging Designer / Structural Packaging Designer to redesign the pod storage shown in the attached image and develop a manufacturing-ready cardboard version.
The original product is made of plastic. We want to manufacture a similar product using thick, rigid cardboard / paperboard, with a flat-pack design so that it can be transported efficiently and assembled locally.
The final design must be practical for real-world production, not just a visual/3D concept.
Our Main Objective
We need a cardboard pod storage that can be:
• Manufactured from thick and rigid cardboard/paperboard
• Supplied to us in a flat, unfolded condition
• Easily transported and stored
• Folded and assembled locally
• Assembled with glue and/or suitable locking/interlocking elements
• Strong enough to hold coffee pods securely during normal use
• Produced without requiring a plastic injection mold
We need a designer who can develop the complete structural design and technical drawings/dielines required for manufacturing.
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Existing Product / Reference
Please see the attached image.
The image shows the general shape and concept of the pod storage we want to reproduce in cardboard.
Each individual storage section should accommodate approximately 6–7 coffee pods.
The designer may improve the internal structure and folding/locking system if necessary, as long as the final product remains similar in function and appearance.
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Required Design
1. Individual Storage Module
Each pod storage should be designed as an individual module.
The top and bottom sections should be separate cardboard components.
One complete storage module will consist of:
• 1 × Top component
• 1 × Bottom component
We will assemble/glue the top and bottom components together locally.
The design should therefore allow the two components to be manufactured separately and supplied flat.
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2. 2-Unit Version
We need a version consisting of:
2 top modules + 2 bottom modules
The two individual modules should be connected/assembled together to create one 2-unit pod storage set.
The designer should develop a suitable:
• Side connection
• Joining system
• Locking/interlocking mechanism
• Glue flap system, if required
The connection should be strong and practical while still allowing the product to be supplied flat.
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3. 4-Unit Version
We also need a larger version consisting of:
4 top modules + 4 bottom modules
The 4-unit version should function as one complete storage/merchandiser.
The connection system should be designed specifically for the 4-unit configuration.
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Reference Overall Dimensions
The current reference dimensions for the 8-box merchandiser (4 top + 4 bottom) are approximately:
14.6" L × 17.8" W × 17.3" H
Each individual storage section should accommodate approximately:
6–7 coffee pods
The designer should determine the exact dimensions of the individual compartments and all structural elements based on the actual pod dimensions and the required final configuration.
Important: The above dimensions are reference dimensions. The designer should optimize the internal and external dimensions to ensure proper strength, stability and manufacturability.
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What We Need From the Designer
This is the most important part of the project.
We do not need only a 3D model or a nice-looking concept.
We need a complete manufacturing-ready structural design that we can send directly to a cardboard manufacturer.
The final deliverables should include:
1. Complete Technical Drawings
Detailed technical drawings showing ALL dimensions, including:
• Overall dimensions
• Individual module dimensions
• Internal compartment dimensions
• Cardboard blank dimensions
• Fold lines
• Creasing lines
• Cutting lines
• Glue flaps
• Locking tabs
• Slots
• Connecting elements
• Joining points
• Overlapping areas
• Assembly points
• Tolerances where necessary
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2. Flat Dieline / Cutting Pattern
Provide a complete flat unfolded dieline for every cardboard component.
The dieline must clearly indicate:
• Cut lines
• Crease/fold lines
• Perforation lines if required
• Glue areas
• Folding direction
• Locking tabs
• Slots
• Connection points
The design should be suitable for CNC cutting / die-cutting / digital cutting.
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3. Cardboard Specification
Please recommend the appropriate material, including:
• Cardboard/paperboard type
• Recommended thickness
• Recommended GSM
• Approximate stiffness/strength requirements
• Whether corrugated cardboard, solid board, folding boxboard, greyboard or another material would be more suitable
We want the thinnest/lightest material possible while still maintaining sufficient rigidity and strength.
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4. Assembly System
The designer must determine the best way to assemble the product.
For example:
• Folding
• Gluing
• Locking tabs
• Interlocking slots
• Combination of glue + mechanical locking
The final design should be easy to assemble manually.
We will manufacture the flat components and assemble them locally in Azerbaijan.
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5. 3D Assembly Model
Please provide a 3D model/render showing:
• Fully assembled individual module
• 2-unit configuration
• 4-unit configuration
The 3D model should clearly demonstrate how all parts fit together.
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Required Files / Deliverables
At the end of the project, we expect to receive:
• Manufacturing-ready PDF technical drawings
• 2D CAD files – preferably DXF/DWG
• Editable vector files – AI / EPS / SVG if applicable
• 3D CAD model – STEP/IGES or similar
• 3D renders showing the assembled product
• Complete flat dielines
• Assembly instructions
• Material/cardboard specification
• Recommended cardboard thickness/GSM
• Complete dimensions and tolerances
• Cutting and creasing specifications
All dimensions must be clearly marked and understandable by a manufacturer.
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Important Requirements
The designer should have experience in at least one or more of the following:
• Structural packaging design
• Cardboard product design
• Paperboard engineering
• Packaging dielines
• POS/display stand design
• Retail merchandiser design
• Flat-pack product design
• Die-cut cardboard structures
• Product development for manufacturing
Experience with cardboard retail displays / merchandisers / organizers would be a strong advantage.
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Prototype / Manufacturing Consideration
The design must be developed with actual manufacturing in mind.
We want to avoid unnecessary complexity and expensive tooling.
The ideal solution should be manufacturable using processes such as:
Printing (if required) → die-cutting/CNC cutting → creasing → folding → gluing
We also want the final product to be economical to manufacture and transport.
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Important: Designer's Responsibility
The designer should not simply copy the plastic structure.
We expect the designer to engineer a suitable cardboard structure that achieves the same function.
If certain elements of the original plastic design are not suitable for cardboard, you should propose a better structural solution.
The final design should be:
Strong + Stable + Easy to Assemble + Flat-Pack + Economical to Manufacture
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Project Goal
Our goal is to develop a commercially usable cardboard pod storage/merchandiser that we can manufacture in quantity and supply to our customers.
Therefore, the final technical drawings must contain enough information for a cardboard manufacturer to produce the product without having to redesign the structure themselves.
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When Applying, Please Include
Please provide:
1. Examples of similar cardboard structural/product designs you have created.
2. Examples of flat-pack cardboard products or retail displays you have designed.
3. Which software you use (CAD / SolidWorks / AutoCAD / ArtiosCAD / Illustrator etc.).
4. Your estimated time to complete the design.
5. Your fixed project price.
6. Whether you can provide a prototype-ready design.
7. Please explain briefly how you would approach this project.
Please apply only if you have experience creating technical/manufacturing drawings for physical products.
The attached image is the reference product we want to convert from plastic to a manufacturing-ready cardboard design.