Redesigning Ferrero Rocher Packaging

As a product designer, I tackled a unique challenge for Ferrero Rocher. The existing plastic candy box needed an update, but the client likely had a mold in production without complete 3D data. I collaborated with the toolmaker to reverse-engineer the design.

I opted for touch probe scanning over laser scanning due to the challenges posed by highly reflective and transparent plastic surfaces. Since my goal was to create curves for sectioning on the scan data rather than obtaining a complete 3D point cloud, the touch probe scanner provided a suitable solution. While it may not capture the entire surface shape, it effectively captured the necessary data for generating curves and facilitating the creation of a NURBS surface.

This project predates my time at Volvo Cars (joined in 2011). It was here, and during the Royal's Animal Farm project, that I truly fell in love with 3D visualization. This ignited my passion for the world of polygons.


This image shows the modeled NURBS surface with the original scan points overlaid. I used these points to create curves in Rhino and meticulously adjusted them (massaged) to achieve the desired curvature with minimal points, ensuring a smooth final result.

This image showcases my Rhino 3D working file. The file already includes the modeled plastic tickets and the top lid assembled with the bottom half.

Similar to the Royal's Animal Farm project, these 3D renders were created for personal skill development in materials, textures, lighting, and composition. As I delved deeper into visualization, I relished finally seeing my designs come to life in a realistic context with appropriate materials. These renders represent a purely self-directed learning project.

To optimize efficiency, I opted for displacement painting instead of modeling the intricate details of the yellow oval housing for the chocolate placements. This approach proved highly successful.

Modo 3d with displacement painted.

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