Problem: Technical Precision Meets Consumer Experience
How do you package cutting-edge sanitation technology in a way that feels premium, accessible, and trustworthy? UVX needed a complete system—packaging, manuals, technical documentation—for their first flagship product: a smart UVC lamp with patented 666nm filter technology. The challenge was multilayered: the unboxing had to communicate innovation and quality, the installation process involved complex hardware setup requiring regulatory warnings, and all materials needed to serve both expert installers and first-time users.
The constraints were strict:
Regulatory compliance: Safety warnings, installation steps, and technical specs had to meet legal standards
Accessibility: Non-experts needed to successfully install specialized lighting hardware
Brand positioning: As a Vancouver-based tech startup, UVX needed materials that communicated innovation, precision, and local roots
Sustainability: Minimize waste while maintaining premium feel
Cost effectiveness: Locally sourceable materials where possible
The core problem became: How do you create a cohesive system where packaging, instruction manuals, and technical docs all reinforce the same brand values while serving vastly different functions?
The solution was to develop a unified visual language that could flex across contexts—bold and sophisticated for packaging, clear and precise for manuals, detailed and compliant for technical documentation. Rather than treating these as separate deliverables, I designed them as a family of materials where form, color, typography, and iconography worked together to build trust and clarity.
Core design system:
Color story: Deep navy blue (wavelength of 666nm UVC light) as primary brand color, paired with clean whites and sustainable kraft materials
Topographical identity: Vancouver's topography rendered as wavelength-style patterns, connecting the product to its geographic roots while reinforcing the "light technology" narrative
Material hierarchy: White sleeve (premium reveal) over kraft box (sustainable practicality) over navy insert (protective drama)
Icon system: Custom-illustrated hardware diagrams that translated across packaging, manuals, and quick-start guides
Deliverables: External packaging (sleeve + kraft box + navy insert), comprehensive instruction manual, quick-start guide, technical specification sheets, regulatory documentation, and app integration guides.
Packaging Design & Unboxing Experience
First impressions matter
The packaging needed to communicate that ZENER was a serious piece of technology, not a consumer gadget. The unboxing sequence was designed as a reveal: white outer sleeve printed with Vancouver topography in wavelength patterns, sliding off to expose a clean kraft box, which opened to a deep navy interior cradling the device.
Why this structure?
The sleeve: Showcased the sleek ZENER hardware through a die-cut window, giving customers a preview while protecting the product. This approach was also cost-effective and allowed local sourcing in Vancouver.
The kraft box: Tied into sustainability values without sacrificing structural integrity. The natural material contrasted beautifully with the high-tech product inside.
The navy insert: Custom-molded to hold the device securely, this layer added drama to the unboxing while referencing the 666nm UVC wavelength through color.
Visual language: Every surface carried meaning. The topographical wavelength pattern wasn't decoration—it was Vancouver's actual landscape rendered as light frequency data, connecting UVX's local identity to their technical innovation. Typography was clean and sans-serif, emphasizing precision. Graphic treatments used bold hierarchy to guide the eye from brand identity to product features to regulatory information.
By focusing design effort on the sleeve and insert rather than printing directly on the kraft box, we reduced ink waste and kept the base packaging recyclable. The modular design also meant components could be reused or replaced independently for future product iterations.
Instruction Manual Design
Making complexity accessible
The instruction manual was the most challenging piece. ZENER's installation involved mounting hardware, electrical connections, filter installation, and app pairing—all requiring precision while adhering to safety regulations. The manual needed to serve two audiences simultaneously: professionals who could skim for key specs and homeowners installing their first smart lighting system.
Visual hierarchy: Each installation step was broken into numbered phases with large, clear illustrations. I created custom hardware diagrams that showed the ZENER device from multiple angles, with components labeled and connection points highlighted. These illustrations had to be technically accurate enough to guide installation while remaining visually approachable.
Regulatory compliance: Safety warnings, electrical specifications, and compliance information were integrated throughout rather than buried in fine print. I used color coding (red for warnings, blue for tips) and iconography to make critical information scannable. All regulatory text met legal requirements while remaining as readable as possible.
Progressive disclosure: The manual was structured so users could follow a "quick path" for basic installation or dive deeper into advanced configuration. Fold-out pages provided detailed spec sheets without interrupting the main flow.
Technical Documentation Suite
Precision for different contexts
Beyond the comprehensive manual, the project required technical specification sheets for installers and distributors, plus a quick-start guide for users who wanted immediate setup.
Technical spec sheets: These documents served electricians, building managers, and regulatory inspectors. I designed them with dense information hierarchies: product dimensions, electrical requirements, photometric data, filter specifications, and compliance certifications. The layout used tables, diagrams, and callouts to make data quickly parseable while using generous whitespace and clear section headers to prevent overwhelming readers.
Quick-start guide: A single-sheet fold-out designed for users who wanted to get ZENER running immediately. This focused on the minimum viable installation: mount, connect, pair with app. Illustrations were simplified versions of the manual diagrams, with QR codes linking to video tutorials and full documentation.
App integration materials: Since ZENER connected to a smartphone app for control and scheduling, I created supplementary guides showing the pairing process, interface navigation, and troubleshooting common connection issues. These materials bridged physical installation with digital setup.
Hardware Illustration & Diagram Development
Translating 3D complexity into 2D clarity
Creating accurate hardware illustrations was one of the project's biggest challenges. The ZENER device had multiple installation configurations depending on mounting location, electrical setup, and filter orientation. Each diagram needed to show spatial relationships, connection points, and assembly sequences without overwhelming users.
Illustration approach: I used exploded-view techniques to show how components fit together, step-by-step progression shots to demonstrate assembly sequences, and multiple viewing angles to clarify mounting positions. Each illustration was labeled with numbered callouts that corresponded to written instructions, creating redundant information pathways so users could follow either visual or text cues.
Regulatory accuracy: Hardware diagrams had to meet safety standards—showing proper wire routing, correct screw placements, and safe clearance distances. I worked closely with UVX's engineering team to ensure every detail was technically correct while translating complex 3D information into approachable 2D graphics.
Consistency across materials: The same illustration style and iconography appeared across packaging, manuals, quick-start guides, and technical docs. This visual consistency meant users encountered familiar graphic language regardless of which material they referenced, reducing cognitive load and building confidence.
Brand Integration & Material System
Vancouver roots, global standards
Throughout all materials, I wove in UVX's identity as a Vancouver-based innovation company. The topographical wavelength pattern appeared on packaging, manual covers, and documentation headers—always subtle, never overwhelming. This created visual continuity while reinforcing the brand's local pride and technical expertise.
Material choices reflected values:
Kraft packaging = sustainability commitment
Navy insert = premium protection + UVC wavelength reference
Matte finishes = anti-glare for printed materials, sophisticated tactility for packaging
Locally sourced components where possible = reduced shipping impact, supported local manufacturing
Typography and color system: I established clear rules for how the navy blue, white, and kraft tones interacted across contexts. Packaging could be bold and graphic; manuals needed clarity and breathing room; technical docs required dense information display. The same typeface family (clean sans-serif) adapted across all uses, maintaining brand consistency.
Cost effectiveness: By designing the sleeve as a separate printed piece over an unprinted kraft box, UVX could produce small batches locally without expensive full-box printing runs. The modular approach also meant future product variations could reuse the base packaging with new sleeves.
Reflection
Designing across the full journey
This project taught me that packaging isn't separate from documentation—they're all part of one continuous user experience. Someone doesn't just unbox a product; they install it, reference the manual, troubleshoot issues, and consult specs. Every touchpoint is an opportunity to build trust, reduce friction, and reinforce brand values.
What I learned:
Regulatory design is creative work: Compliance requirements aren't constraints that kill creativity—they're design problems that demand inventive solutions. Making safety warnings legible and non-intimidating was as much a design challenge as creating a beautiful unboxing.
Illustration as communication: Custom hardware diagrams bridged the gap between technical precision and user accessibility. Spending time on accurate, clear illustrations paid off in successful installations and reduced support needs.
Sustainability and premium aren't opposites: The kraft box proved that eco-conscious materials can feel high-end when paired with thoughtful structure and visual design.
Systems thinking matters: Designing packaging, manuals, and docs as a unified system (rather than separate projects) created coherence that elevated the entire brand experience.
What I'm proud of:
Creating materials that served both experts and novices without compromising either experience. The manual worked for professional electricians who needed quick specs and for homeowners installing smart lighting for the first time. The packaging communicated innovation and care. The technical docs met regulatory standards while remaining human-readable.
This project reinforced that good design serves both function and feeling—the packaging needed to protect and impress, the manuals needed to instruct and reassure, and all of it needed to reflect UVX's commitment to innovation, precision, and thoughtful execution.
