Sphero BB-8
Goal
Led the structural design and development of the premium packaging system for the Star Wars BB-8 App-Enabled Droid, managing the project from initial concept through mass production and transit validation.
Scope & Approach
Designed a high-fidelity rigid setup box featuring precision-engineered high-density foam inserts to secure the spherical robot and magnetic head. The approach prioritized a "collector-grade" unboxing experience, and organized accessory layering to guide the user through a dramatic reveal while ensuring the sensitive internal gyroscope mechanism remained protected. Known issues to overcome: ensure customer connected app to droid correctly, have BB8 and base in the correct orientation in product reveal, and protect fragile antennas.
Impact
Engineered a custom foam density profile that absorbed transit shocks, protecting the floating internal drive train and eliminating transit damage.
Optimized the internal layout to minimize package volume, improving shipping efficiency and maximizing retail shelf density at major retailers like Apple and Best Buy. Created a durable, display-worthy package that doubled as a permanent storage solution for the droid, encouraging retention rather than disposal.
Work done while at Veritiv with collaboration of the Sphero team.
Hang Tag
The custom-molded Sphero logo hangtag reinforces branding while offering retail versatility. The structure features a dedicated cavity, allowing the tag to fold flat for shipping—optimizing master pack density and preventing damage
Foam
We selected this foam specifically for its premium tactile quality, reminiscent of a high-end sneaker sidewall. Beyond aesthetics, this material solved critical engineering challenges. The foam provided a precise friction fit that immobilized the spherical unit during transit, preventing rotation and ensuring a consistent "face-forward" presentation for every unboxing. This choice also eliminated the risks of abrasion and paint transfer often associated with molded fiber, while the deep matte black finish created high visual contrast to make the hero product pop.
Accessory Box & Quick Start Guide
A decoupled accessory box design streamlined the kitting process and future-proofed the package for global cable variations, while keeping the unboxing focus purely on the droid
The quick-start guide rests on a shoulder within the rigid box, serving a dual purpose: it acts as a final protective buffer for the droid during transit and dictates the unboxing choreography. By placing the instructions at the top layer, we ensured immediate visibility, allowing the user to remove the card and place it alongside the droid for a seamless, side-by-side setup and app synchronization process.
