Recently, I designed a CD cover/packaging for a project and was really keen on using the ’slide’ mechanism which isn’t totally original I must admit, but does look cool and impressive. Plus, for the particular genre in question ‘Russian Ballet Classics’  I thought would be a gracious and elegant solution in which the packaging would be part of.

After much searching, I couldn’t find any templates online at all, only  a copy of the patent on Google which despite all the complicated diagrams and charts – I was none the wiser. So, I figured it out myself, so now you don’t have to! Wahhoooo!! It took a few attempts to get right as the CD tray (borrowed from a Albert Hammond, Jr album) kept getting stuck or was a few millimeters out and then wouldn’t quite drive flush. But it was well worth it in the end.

I used Adobe Illustrator CS4 although I don’t know if it will work on a earlier version, I’ve not tested it. If your having problems, contact me and I will try and help. The dimensions I used where to accommodate a standard 12cm CD. The file provided can easily be modified to fit your project, just be accurate with folds and your choice of stock will make a big difference – example for thick card stock such as 400gsm  will need a deeper/heavier/wider fold than say 100gsm paper stock. As this is demonstration is just a tutorial on the concept and workings of the BurgoPak, I haven’t included a actual CD-tray. You can pick these up at most decent music stores usually quite cheap. Or they come free with some albums…

Pull Right, Push Left

Essentially, the Burgopak is made up of  ‘Belt Drive‘ that is wrapped around a ‘Integral Wall‘, which is contained within a ‘Slip Case‘ – the artwork on the outside of the CD pack for example. As you pull the tab  in a draw like fashion on the right side, the CD tray will reveal itself on the left side. This is the fundamental and intrinsic idea of the BurgoPak design, yet uses the rudimentary concept of circular motion as the engine. It’s an absolute stroke of genius in my opinion, and very inspirational. Burgo Wharton – I could kiss you.

You will need:

• Sharp Scalpel
• Cutting Mat
• Mac or PC
• Illustrator cs4 -( program that will read and edit ai. files.)
• Ruler (x2 is better for a decent fold)
• Double Sided Tape – (or glue)
• A4+ Printer
• 250gsm+ Stock/Paper/Card
• Thin plastic bag (I used a keep fresh seal bag, A4 size, I dunno what they’re officially called – see picture)
• Delicious Tea and/or Coffee.

{1} Download the AI. File BurgoPak_CD_Templates.ai

Download the file and apply your artwork as per your requirements. I have purposely kept my artwork on/in the file to help you understand the artwork locations on the front and back sides of the CD SLIP Case.

{2} Print, Cut and Fold

Print and cut out your artwork. Fold along the red dashed lines with the rounded blunt end of your scalpel – apply a good, decent amount of pressure. If you have two thin metal rulers, tape them together with a 1mm gap. This will make a decent groove and registration line for your folds – align the red dashed line over the two rulers and run the scalpel between the two rulers and apply great pressure.  Flip the artwork over and do the same on the reverse. You’ll have a perfectly straight fold, with a good bend to integrity ratio. You don’t have to, but it’s easier and quicker – but it’s not absolutely essential.

Fold/Score with Scapel handle and two rulers

Repeat for all cut outs and folds accordingly, remembering to sip your tea and/or coffee as when required – perhaps changing CD’s in between etc…

{3} Build the Mechanism

So, you’ve cut n folded the parts now it’s time to move onto the making the mechanics of the pack. This bit is the genius of the invention, once you’ve sussed the general workings, you can scale and modify till your heart (or client) is content. Tape with the double sided tape the tab and stick the two sides to form ‘the mechanical wall’…

In the file I’ve included a container for the booklet to go inside the CD pack, often containing the thank you’s, copyright info etc. This was needed for my project, but maybe not yours. BUT If you choose not to  include a booklet, you must replace it with a blank tab, or card or even another CD tray otherwise the pack wont function, as there will be nothing to use as a pull-tab!

This will act as booklet + pull-tab and will be pulled from the right side and therefor will go in the housing like so…

Booklet pull-tab lives the inside mechanical wall

Lovely. Now lets get some action going and get the Belt Drive involved. Cut your plastic ‘forensic’ bag or something similar in consistency, to 30cm//11.8inch in length and 10cm//3.9inch in width. [These measurements are for this project remember. If your altering in dimensions just double the length and plus 2cm//0.7inches, this is more than actually needed but it's much easier to have to much and trim accordingly.] Thread through the ‘tunnel’ and then back over the top, like so…

Thread the belt through the tunnel...

...all the way, then back ontop

Seal with our friend Double Sided tape again, but make sure it’s not too tight on grip or the movement will be far too restricted or stiff and the belt may even rip and fall apart. You should have abit extra like in the picture, use this to test the functionality and smoothness of the motion. The belt should stop at the end.

Belt stops at the end.

Excellent team, we’re making progress – the hardest part is pretty much over now. Add the Double Sided tape to the LEFT Booklet Pull-tab. Important! – where to place the tape is the point of final destination of travel. i.e will not go any further. So, if you place the tape right in the middle that’s where it’ll stop. With experimentation,  this can work to achieve a semi-concealed effect which maybe a suited to your project but for the purpose of this tutorial it’s vital to be positioned on the left.

Tape Double Sided tape on the left on the booklet holder/pull tab...

Remove the white part of the tape so it’s ready to stick to something. Really carefully and from the right feed inside the housing to the left side.

From the Right, underneath to the Left

'Save as houses' inside and ready...

Great, getting there. Tape the right side of the Belt on the top surface as the picture above indicates. Now, simply remove the white tape and align the CD-tray layer on top centrally.

CD-tray placed ontop

Now is a good time to test, pull the tab on the right. The CD-tray should be moving left.

Pull right, it moves left!

Well done team! that’s it. Lets wrap this up. Literally.

{4} Wrap up and seal with CD Artwork

Cut and fold the sides as the file describes. Test you have got your sides the correct way round – the tapable tab should be at the top. Add the Double Sideded tape, but don’t finalize just yet..

Tab is at the top

Align and make sure your happy with the registration – test that the ends meet well with and snug. If your design is a few millimeters out don’t and the ends don’t quite join, adjust your design on the computer and add the difference of mm on your design (or) check your folds/crops and reprint. It took a few attempts to get right to begin with, sometimes accidentally cutting too much or not enough et cetra… After all, this is what proofing and prototyping is all about – discovering problems and solving them. If your the ends don’t join don’t force them, by doing this the grip will be too tight and the pull system just wont work.

Make sure your 100% happy and peal off the white tabs and complete.

Finshed

Congratulations! show this to your clients and they’ll love you for it.

FREE! BurgoPak Illustrator CS4 Templates for you to use in your projects. But remember this design is patented and may not be used by any company or sell any packaging with this works inside, if they have not bought the rights from the company BurgoPak.