After initially developing a different advent calendar concept for a major UK retailer, some important buying team feedback switched the creative direction to focus on a woodland theme inspired by a festive animal illustrations found when compiling the initial research.
A set of 12 animals were selected and designs for slot-together 3D models were produced for each animal character. Each structural design was prototyped, tested and modified to make each one more recognisable and help ease of assembly by the end user.
The set of animals included: a Deer, a Fox, a Badger, a Hedgehog, an Owl, 2 Rabbits, 2 Squirrels, a flock of Birds, a Snowman, and a Christmas Tree (admittedly the last 2 are not animals but were part of the illustration used as inspiration and were requested). The Fox character was developed first, using both digital 3D modelling and prototyping.
Similar construction methods were used for the rest of the characters with digital 3D models being used to check the assembly before all the structural designs were laser cut.
The laser cut models were checked for tolerance. Sadly the service used produced a lot of soot on the burnt edges of the grey board material. The width of the laser was also much greater than expected which resulted in the parts being a very loose fit.
At this point it was decided that to minimise tooling costs, extend the product life (allowing the calendar to be reused), and make the animals more robust, a PVA foam was to be used instead of the grey board. The 3D models were all updated to reflect the new material thickness and the designs were sent to the factory to produce samples.
The components were laid out on a single sheet for production, and separated in to their individual compartments at the packing stage. Minimal artwork was added to compliment the simplistic outline style of the models.
The packaging was based on an existing advent calendar design, but incorporated a new fold-down front flap to create a snow scene for the 3D characters. Below was the mock up visual used to check door position and allow for the vac tray design to be confirmed.
The below production sample was assembled for final product photography, to add to back of the packaging artwork.
UPDATE: The Woodland Advent Calendar is now on sale as Tesco (October 2021) - https://www.tesco.com/groceries/en-GB/products/309699499
