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Product & Packaging Design

Products for the NFL, NBA, MLB and NHL plus 50 collegiate universities designed by Steve Hall

nfl-footballfootballOver the years, in addition to packaging designs, I have designed dozens of products each beginning with a prototype. A prototype is a realistic version of the product that can be reviewed, further modified or, if perfect, used as a master from which final production molds and packaging can be created. Besides sculptural abilities, I am a skilled with various molding and casting techniques as you can see in these shots.

Here on this page are a few photos from products with national distribution in Wal-Mart, Target, and many more stores. Products I designed were licensed with the National Football League (NFL), National Basketball Association (NBA), National Hockey League (NHL) and National Baseball Association (NBA), plus approximately 50 major American universities for their football, baseball, softball, basketball and soccer teams. The soccer balls were also sold by several soccer teams abroad (they call them "football" teams out there as you know).

Here are just a few samples of my collegiate products. The basketball, football and soccer were sculpted by me and manufactured in China based on my prototypes (see below for more on 3-D sculpting).

The product is a 3D window decal.

packaging-back

Back of the ball packaging. I also shot all the photos, of course.

 

college-team-product-samples

 


Products for Bass Pro and Cabela's designed by Steve Hall — Largemouth Black Bass

bass-packaging

This Largemouth Bass decal was launched in 2006 and won 1st place in the September/October Issue of P-O-P Design Magazine. I designed the decal, packaging and painting details on the fish. The fish itself was molded from a taxidermist's model. 

The product was sold in Cabelas, Bass Pro, and through numerous other catalog and online retailers such as Ebay.

The product was designed for fishermen to apply to the rear window of their vehical to promote their favorite sport.

 3D-fish-window-decal

 

bass-packaging-front   bass-packaging-back
Bass packaging card, front   Bass packaging card, back

 


Whitetail Deer Window Decal

I designed Whitetail Deer product, decal, card and blister packaging in 2005. The packaging used a blister (preform plastic cover for the deer head) is not shown here. You can see how the actual deer was sculpted below.

 deer-packaging-front    packaging-back
Deer packaging card, front   Deer packaging card, back

 

In March of 2007, I was asked to travel to China to coordinate with production staff in five factories and ensure the designs for the deer, bass, football, soccer and basketballs were faithfully replicated.
stevehall-in-china product-injection-mold
steve-in-china shenzhen-factory1 shenzhen-factory-worker

 


 

Product & Prototype Sculpting in 3-D

deer-packaging

 

3-D Deer Decal Product Design

This next product was a 3-D Deer Decal that was sold in Cabelas, Bass Pro and more. I came up with the idea and developed and desisigned the prototype, a unique blend of 2D and 3D art. I also designed the packaging, of course and oversaw production.

We also produced a fish (largemouth bass) for fishermen. For that we used a taxidermist's model, molded from a real fish.

 

 deer master
This is the original clay sculpture I did of a whitetail deer. A rubber mold was made from the original clay piece.
 deer-profile
Then from the new mold several exact copies were cast in plastic. I used an airbrush to paint two plastic copies in realistic detail. Here are some more views.
deer-front
deer-back
deer-right
deer-left
I later decided the ears were a bit too long and so I adjusted them in the prototype.
 deer
 comparison
Here you can compare the original hand-painted master (bottom) with a production sample (top) made at our factory in China. They don't have whitetail deer, so they had to depend on my prototype to get the painting right. You can see some simplification, but it's still pretty darn good.
 deer-cling
Next, I designed background art: the deer's body in the wilderness. This arc-shaped decal is what the deer's head is bonded to. Then the whole assemply goes on the back of a hunter's window.
 deer-on-truck
They were sold in Bass Pro, Cabelas, various other sporting/hunting stores, and are still sometimes available on Amazon.com.

 

Football, Basketball and Soccer

carving
In this sequence, I created a series of products involving a soccer ball, basketball and football that were sold in Wal-Mart, Target, and many other stores. In this sequence, the original sculpture was created in plaster, then carved and sanded.
sanding
Automotive Bondo was used to correct any imperfections until the master was 100% perfect.
mixing
A rubber mold was is created using light purple silicon rubber. We will use the cardboard box for a mold.
setting-up
Into the silicon mold, we pour resin around a styrofoam ball to make an exact duplicate of the original master. At this point I am working on the basketball version.
de-molding
The new duplicate casting is freed from the mold. 
empty-mold
And of course it is a perfect copy of the original.
shaping
Now the excess styrofoam can be removed from the shell, so as not to confuse factory workers in China who were contracted to mass produce the product.
painting
The prototype is painted using an air brush.
coating
It requires several coats.
detailing
Fine details are added with a paint brush. Now the original master and a painted copy showing how the paint looks can be sent off to the factory for production. 

 


 

3D Ghost and Bat Product Design

I produced these prototypes for the Halloween industry. They were 3D decals to decorate windows. The Ghost, coming to haunt you, appears to be drifting through the glass. While the blood-thirsty bat has crashed through the glass to get at your neck!

 

sculpting
The project was a series of seasonal products.
sculpting2
These prototypes were made of clay. This is still the rough stage.
batmold
With all those interlocking teeth, the bat's lower jaw had to be molded separately from the head.
bat casting
The final plastic casting is a perfect copy of the original master.
bat-in-window
Next a decal was made of the Bat's body and wings. Here it is on a glass door. Yikes!
bat-prototype
Needs some tweaking. Don't care for the red eyes.
bad-bat
Finally set on attractive corpse-like gray eyes to match his wings. With the paint completed, the prototype is mounted to an acrylic sheet for review and mass production.
bat-left
"Nice bat. Go 'way. Far away. We've got no blood here. It all drained out in the 4th Quarter of that last Cowboys game."
bat-right
"Yes, yes! That's it! Fly away. Try Washington DC! You'll find more of your own kind there. Besides, that's where all the blood from the whole country goes!"
ghost-molds
Here's the mold created for the Ghost, which is pictured here upside down of course. This is what's left of you after the bats get through. Here, the first plastic prototype has just been de-molded. A special spray called "mold release" is used to keep the plastic from sticking to the mold.
ghost-in-window 
The Ghost will drift through the window. But first we need to make some adjustments.
adjusting-ghost
The folds don't line up yet so we'll have to adjust the 2D art for the decal.
 ghost-closeup
Now that's how to spook up anyone getting in your Kool-Aid. Below is the final design uniquely combining 2D and 3D elements and patented to scare you.

 ghost-mock-up

 

 

 

 

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Subtle clues you might have found the right creative:

                   

total profits earned

$411,000,000 in sales generated by Steve Hall for clients

43,000,000 total hits on websites designed by Steve Hall Creative

43,000,000 visitors to Steve Hall's websites

         

11,000-displays

11,000 visual merchandizing displays

500,000 words published as a copywriter

500,000 words published
as a copywriter

500 plus keywords on page one of Google by Steve Hall
SEO keywords on
Page One of Google

250

250 print ads in newspapers,
magazines & online

 

153 total brochures and catalogs by Steve Hall

153 brochures and catalogs

 

128-film-video-scripts

128 films and videos scripted

102 websites built by Steve Hall

102 websites

77-tv-spots

77 TV spots

62 logo designs by Steve Hall

62 gorgeous logos

33

33 packaging designs

9 book covers designed by Steve Hall

9 book covers

plus-sign

Plus billboards, business cards, company names, direct mail campaigns, exibitions, outdoor signs, marketing campaigns, Pay Per Click, photography, showroom designs, typesetting and...

1

1 place where all this experience comes together:
Your project.