Alexander EttlDevelopment Engineer (Mechatronics)
Flat-Pack Exhibition System

Flat-Pack Exhibition System

Boxes are boxy because they're packaging, not because corrugated board demands it. The design pushes the material toward rounder, more organic, higher-end-looking forms instead of the same crate everyone throws out. Nobody expects that much quality from a material that usually ends up flattened in the recycling. Clusters of retail-display references: interlocking instead of gluing, large flat surfaces, hidden edges, a single material throughout — the starting point for the construction. Every part got a dimensioned drawing to ISO 2768, with tolerances and a material list — the basis Nextpack could actually manufacture from. Cutting happened at Nextpack, the packaging manufacturer behind the project, not in a workshop. A CNC router brings the honeycomb board exactly to size, so all that's left on-site is slotting it together. The parts simply slot into one another. The whole system goes together in minutes, with no screws or glue at all.

A rolled tube, two end caps and an internal triangular brace for stiffness — pushed together without screws or glue. A trade fair stand lives three days: built up, used, taken down. Almost all the effort sits in the transport before and the disposal after.

Plinth, shelf and partition walls in honeycomb board ship flat and slot together on-site without tools, because packed size and cutting waste drove the design, not the silhouette. Plinth, shelf and table come off the same board: one material, no fittings, no mixed joints. Whatever is left after the fair goes back into the same cycle, sorted by material alone.

Cardboard starts out boxy
Moodboard: references for the stand
Dimensioned production drawings
Cut at Nextpack
Simple slot-together assembly
The pillar, taken apart
A trade fair stand lives three days
Ships flat, assembles without tools
Plinth, shelf and table from two board types
Flat-Pack Exhibition System
Cardboard starts out boxy

Moodboard: references for the stand

Dimensioned production drawings

Cut at Nextpack

Simple slot-together assembly

The pillar, taken apart

A trade fair stand lives three days

Ships flat, assembles without tools

Plinth, shelf and table from two board types

At a glance

Context
Semester project with a packaging manufacturer
Period
Summer 2023 · 3 months, ~150 h
Role
Team of three with Helena Dinkhoff and Nicolas Schmeding, supervised by Prof. Kostas Medugorac and Hannah Steinmetz.
Disciplines
Industrial design and Mechanical
Evidence
a built prototype and manufacturing process

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