Structural Packaging / Prototyping

OSOK Limited Edition

A laser-cut, laser-engraved wood packaging system for a limited cigar release — carried from raw prototype through hand-built proofs to the final production box.

Final OSOK laser-engraved wood box, closed and open
Client
OSOK × Industrial Cigar Co.
Role
Structural design & physical prototyping
Materials
Laser-cut birch plywood, finger-joint construction, laser-engraved graphics
Process
Iterative physical proofing, four SKU variants

Where INCH is a print-and-fold structure, OSOK is a build — a finger-jointed wood box designed to be laser-cut flat and assembled without hardware. That construction method meant every dimension had to account for kerf loss and joint tolerance before a single physical unit existed, then get corrected against what the laser actually cut.

From raw proof to finished box

Early proofing ran in unfinished birch — four box variants, hand-labeled by count and size, checked for fit, hinge action, and how the lid sat once loaded. That stage exists to catch what a CAD model can't tell you: whether a friction-fit lid feels right in the hand, and whether the joinery holds under repeated opening.

Final production

The finished box carries a full laser-engraved graphic across the lid — a heavier, more custom treatment than the proofing stage, made possible once the structural tolerances were locked. It's the same finger-joint system throughout; only the surface treatment and graphic complexity change between proof and production.

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