Cardboard Carrier

I: Exploration of Corrugated Cardboard

Some initial sketches to plan out the construction of the cardboard corners. These helped me visualize what shapes to cut out before physically experimenting.
Five cardboard box corners I made with the purpose of exploring the medium and evaluating methods of adhesion. I will refer to the corners as “Corner #1–5” in which Corner 1 is furthest to the left, Corner 2 is to its adjacent right, and so on.

II: Creating a Model (“Dummy”) of the Object

Scans of my formal study and the preliminary “plan” for the construction of the dummy.
L: the uneven edge of the cardboard that came with cutting along the flutes. R: using a small model to explore the conical shape of the neck of the bottle.
I realized that the cardboard piece had to resemble a rectangle a lot more since the neck is not very tapered.
Attention to detail: rounded edges of bottle created by multiple score lines
Troubleshooting through the measurement errors I made in creating the neck and cap of the dummy.
The most difficult part: the transition area.
Staged photographs of my dummy + comparing it to my actual object.

III: Preliminary Models of the Special Carrier

After determining the neck hole as an area of support for the bottle, I cut out tabs to connect the “halfway point.” This obviously won’t sustain the bottle — this led to the use of a slot instead.
After threading the end of the cardboard through the slot I cut out, I realized that the tab needs to be inserted further down the front panel than I anticipated.
I created these square borders intending it to go around the bottle in another model, but I ended up using them as a support in my final model. The rounded square cut out from square pieces creates a wall around the bottle so it doesn’t slide around when the carrier inevitably swings. This is the only place I used an adhesive.
Staged photos with a revised (thinner) handle.
Some exploratory ideas about approaching the handles differently, new curved/angular forms, etc. I still ended up sticking with this general mechanism after positive feedback, but these were legitimate considerations that did not make it past the sketch.

IV: Revision 1

Revision 1 laid next to the preliminary model to determine slot and fold line placement.
A basic overview of my intentions with Revision 1.
Sketches exploring other handle and base possibilities.
I hot glued the modified rings to the long piece of cardboard. This remains the only area that requires adhesive in my carrier. The masking tape is a temporary fix for the area of cardboard I accidentally bent.
I did not plan the cut-outs I made on this model explicitly, but I made sure to consider both the angular and curved aspects of the vinegar bottle in the shapes of the neck hole, handle, and tab.
I was a lot more aware of the essential “carrying” aspect of the carrier after we were encouraged to ask others to hold our carrier.

V: Revision 2

Left + Middle: I explored using a protruding piece from the “front wall” and a slot on the handle. The cardboard is not sturdy enough/ is unable to maintain its structural integrity with this setup. RIght: I came up with this sliding mechanism accidentally, but couldn’t find a way to secure it so that the tab stays without budging. I thought it was interesting that by pulling the top and bottom of the “wall,” it tightens the tab.
This tab works a lot better (in the prototype, at least). The fit is snug and it gives the user confidence in its security. When done at this smaller scale, the true force of the weight of the bottle on the slot, and the angles that the handles are subject to moving in, is not represented. On the right, I considered using just a square window as the slots for the tab. Although it is just as secure as the slots, my peers commented that it gives them less confidence in the security of the tab.

VI: Revision 3

Documentation of how the tab, slot, and window evolved over these past two models.
I measured my tab/window against this model, measured it against the label placement on the bottle, traced it, and cut it out.

VII: Revision 4

L: using a thick piece of cardboard and bigger slots. This was the easiest to assemble, but it was not super supportive. M: trying to find ways to fold over the stakes so that the stake is more secure in the slot. I ended up ditching this idea in favor of a more secure slot system. R: I realized I could flatten out the stake and in effect, create a much thinner slot — this resulted in the most secure yet relatively-easy to assemble method of securing the platform base.
Because I knew I wasn’t showing this model in discussion, I felt more freedom to draw all over the model to make notes for myself for my final interation.


From L → R: Model 4, Model 5, and Final Model in progress. Active comparison was made in the process of creating all these iterations.
I paid more attention to craftsmanship in this final carrier, but looking back, being more aware of this throughout the iterative process would have led to a cleaner final result. L: “Furry edges of cut-outs. R: Paying more attention to the spacing between each fold line in the handle. I used my small ruler as a point of reference.
The evolution of my special carrier (Model 1~Final).
Detail shots — L: Stacked base held together by two corners. R: Tab threading through modified slot.
Close up of the tab mechanism.
Opening the carrier to take out the bottle.
Placing the bottle back into the carrier.



Carnegie Mellon Design + HCI ‘23

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