Design a package - Fun at-home activities for Kids.

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Design a package

Design and build a prototype package for a small toy using recycled materials, measure and test protection, then add labels and decorations.

Table of contents

Step-by-step guide to design and build a prototype package for a small toy

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DIY Gift Box / How to make Gift Box? Easy Paper Crafts Idea / DIY gift box / gift box / how to make

What you need

Recycled cardboard, small toy, ruler, scissors, tape or glue, cushioning material such as bubble wrap or crumpled paper, colouring materials such as markers or crayons, sticky labels or plain paper and tape, adult supervision required

Step 1

Gather all the materials listed and bring them to your workspace.

Step 2

Choose the small toy you want to protect and package.

Step 3

Measure the toy length width and height with the ruler.

Step 4

Decide how much cushioning space you want to leave around the toy for protection for example 1 to 2 centimeters.

Step 5

Calculate the internal box dimensions by adding the cushioning space to each toy measurement.

Step 6

Draw a box template on the cardboard using the internal dimensions and include tabs for gluing.

Step 7

Cut out the cardboard template along your drawn lines using scissors.

Step 8

Fold the cardboard along the lines to form the box shape.

Step 9

Secure the box edges with tape or glue to make a sturdy container.

Step 10

Make cushioning inserts from bubble wrap or crumpled paper to fit inside the box.

Step 11

Place the cushioning inside the box and put the toy into the cushioned space.

Step 12

Seal the box securely with tape then add a sticky label with the toy name and handling instructions.

Step 13

Decorate the outside of the package using colouring materials to make it special.

Step 14

Test the package protection by dropping it from about 1 meter onto a hard surface while an adult supervises then open the box and inspect the toy for any damage and note any changes needed.

Step 15

Make improvements if needed by adding more cushioning or strengthening the box and repeat the test until the toy is safe.

Step 16

Share your finished creation on DIY.org

Help!?

What can I use instead of bubble wrap or cardboard if I can't find them?

If you don't have bubble wrap or cardboard, use crumpled newspaper or tissue and old socks or foam sheets for the 'Make cushioning inserts' step and repurpose a cereal box or book cover for the 'Draw a box template on the cardboard' step.

My box is floppy or the toy shifts during the drop test — what should I check and fix?

Re-check your ruler measurements and recalculated internal box dimensions from the 'Measure the toy' and 'Calculate the internal box dimensions' steps, add more cushioning during the 'Place the cushioning' step, and reinforce seams with extra tape or glue when you 'Secure the box edges'.

How can I adapt this activity for younger or older children?

For younger kids have an adult pre-draw and pre-cut the 'cardboard template' and supervise the 'Cut out' and 'Test the package protection' steps while they decorate and label, and for older kids have them do precise measuring, template drawing, cutting, and strength testing themselves before sharing on DIY.org.

How can we make the package more special or improve protection beyond the basic steps?

Decorate the outside with a theme and add a carry handle or a laminated sticky label in the 'Decorate the outside' and 'add a sticky label' steps, layer different materials when you 'Make cushioning inserts' for extra protection, and repeat the 'Test the package protection' step after each improvement to compare results.

Watch videos on how to design and build a prototype package for a small toy

0:00/0:00

Here at SafeTube, we're on a mission to create a safer and more delightful internet. 😊

Origami Gift Box | How to Make a Paper Gift Box Easy (DIY Craft) | DIY Easy Paper Crafts For Kids

4 Videos

Facts about packaging design and prototyping for kids

📦 Corrugated cardboard has been used for packaging since the 19th century — it changed how things were shipped!

♻️ Paper fibers in cardboard can usually be recycled about 5–7 times before the fibers get too short to reuse.

✂️ Upcycling old boxes and materials into new packages keeps them out of landfills and gives toys a second life.

🧪 Simple tests like drop tests and padding checks catch the most common causes of toy damage during prototypes.

🎨 Bright labels and fun decorations help a package stand out and tell the toy's story at a single glance.

How do I design and build a prototype package for a small toy using recycled materials?

Start by measuring the toy and sketching a simple box or protective sleeve. Gather recycled cardboard, plastic, or fabric and cut pieces to fit with a bit of extra room for padding. Assemble with tape or glue, adding internal supports or crumpled paper for shock absorption. Test by gently dropping from different heights, note weak spots, then reinforce, decorate, and add labels. Involve kids in each step for learning and fun.

What materials do I need to make a recycled prototype package for a toy?

Collect sturdy recycled cardboard, cereal boxes, or small cartons for structure; scissors or a craft knife; non-toxic glue and strong tape; cushioning like crumpled paper, bubble wrap, or fabric scraps; a ruler and pencil for measuring; markers, stickers, or paints for labels and decoration. Optional: rubber bands, string, and a small scale or stopwatch for testing. Use safe, age-appropriate tools and supervise cutting steps.

What ages is designing and building a prototype package suitable for?

This activity suits children about 5–12 years with adult guidance. Ages 5–7 enjoy measuring, decorating, and simple assembly with taped seams; supervise cutting and gluing. Ages 8–12 can handle measuring, planning, and testing with more independence, learning basic engineering concepts. Adapt complexity: younger kids do decorating and stuffing, older kids design protection, run drop tests, and record results to build problem-solving skills.

What are the benefits and safety tips for a recycled packaging prototype activity?

Benefits include creativity, measuring and STEM skills, recycling awareness, and fine motor development. Kids learn testing, iteration, and problem-solving. Safety tips: supervise cutting and hot glue, use child-safe scissors and non-toxic adhesives, avoid small choking hazards for young children, and set a clear testing area for drop trials. Encourage recycling materials and discuss ways to improve protection and sustainability.

Ready to create?

All Activities

Design a package

Design and build a prototype package for a small toy using recycled materials, measure and test protection, then add labels and decorations.

Table of contents

Step-by-step guide to design and build a prototype package for a small toy

0:00/0:00

Here at SafeTube, we're on a mission to create a safer and more delightful internet. 😊

DIY Gift Box / How to make Gift Box? Easy Paper Crafts Idea / DIY gift box / gift box / how to make

What you need

Step 1

Gather all the materials listed and bring them to your workspace.

Step 2

Choose the small toy you want to protect and package.

Step 3

Measure the toy length width and height with the ruler.

Step 4

Decide how much cushioning space you want to leave around the toy for protection for example 1 to 2 centimeters.

Step 5

Calculate the internal box dimensions by adding the cushioning space to each toy measurement.

Step 6

Draw a box template on the cardboard using the internal dimensions and include tabs for gluing.

Step 7

Cut out the cardboard template along your drawn lines using scissors.

Step 8

Fold the cardboard along the lines to form the box shape.

Step 9

Secure the box edges with tape or glue to make a sturdy container.

Step 10

Make cushioning inserts from bubble wrap or crumpled paper to fit inside the box.

Step 11

Place the cushioning inside the box and put the toy into the cushioned space.

Step 12

Seal the box securely with tape then add a sticky label with the toy name and handling instructions.

Step 13

Decorate the outside of the package using colouring materials to make it special.

Step 14

Test the package protection by dropping it from about 1 meter onto a hard surface while an adult supervises then open the box and inspect the toy for any damage and note any changes needed.

Step 15

Make improvements if needed by adding more cushioning or strengthening the box and repeat the test until the toy is safe.

Step 16

Share your finished creation on DIY.org

Help!?

What can I use instead of bubble wrap or cardboard if I can't find them?

My box is floppy or the toy shifts during the drop test — what should I check and fix?

How can I adapt this activity for younger or older children?

How can we make the package more special or improve protection beyond the basic steps?

Watch videos on how to design and build a prototype package for a small toy

0:00/0:00

Here at SafeTube, we're on a mission to create a safer and more delightful internet. 😊

Origami Gift Box | How to Make a Paper Gift Box Easy (DIY Craft) | DIY Easy Paper Crafts For Kids

4 Videos

Facts about packaging design and prototyping for kids

📦 Corrugated cardboard has been used for packaging since the 19th century — it changed how things were shipped!

♻️ Paper fibers in cardboard can usually be recycled about 5–7 times before the fibers get too short to reuse.

✂️ Upcycling old boxes and materials into new packages keeps them out of landfills and gives toys a second life.

🧪 Simple tests like drop tests and padding checks catch the most common causes of toy damage during prototypes.

🎨 Bright labels and fun decorations help a package stand out and tell the toy's story at a single glance.