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Cardboard in Disguise: A Masked Project

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Back in 2014 Saxon was approached by the founder of London-based Head of House Designs Charlotte Tiley with a unique request. Head of House is a company specialising in animal masks that are used in a variety of different situations, from mask-making workshops to performance art, films and events. Last year her creations were even on stage at the Wildlife Festival in Brighton worn by musicians in the band Rudimental (pictured below.)

Rudimental Mas

So you may be thinking, what can a packaging manufacturer be supplying to Head of House Designs? Believe it or not, there is cardboard under these works of art, and it is here at Saxon that these animals began their lives.

Charlotte, after investigating various material options to make the mask templates, settled on cardboard as she found it to be one of the “simplest yet effective materials to work with.” When looking for a manufacturer she claimed that “It was about finding a company that could do initial small numbers but grow with demand and be flexible to tight deadlines and Saxon was perfect for this.”

Before she approached us to manufacture the templates, the workshop participants would manually trace a template and cut it out with card. Charlotte loves that the “templates speed up the process so people can spend more time decorating masks!”

Charlotte had a composite tool created for her basic animal mask template which we used to produce the die-cut fittings (a base and two pyramids for ears) whilst the specific animal mask parts were all individually CAD cut. There are too many different animal parts to list but they include a badger nose, bat face, peacock, unicorn horn and an eagle beak (see below.)

Head of House

Ben our Technical Manager here at Saxon said that ‘the main challenge with this project was transforming Charlotte’s hand-drawn templates into KASEMAKE-ready files. We individually scanned each template and then import the files into the software.’ An E flute material grade was used for the mask parts as it was the ideal thickness for mask building, and Charlotte opted for fully recycled Kraft to ensure the masks were as environmentally friendly as possible.

These cardboard templates act as the bare bones of all Head of House’s varied work. When we asked what projects Charlotte has enjoyed the most, she referred to a recent trip taken to Madrid to launch Don Papa’s new rum, which included a masked cocktail party. “The guests made their own masks from a menu of templates linked to the design of the bottle… there were lots of feathers and glitter!”

Although here at Saxon our expertise lies in quality cardboard product packaging, we enjoy working on unusual and diverse projects and especially those that aim to encourage creativity. If you require a bespoke solution, get in touch or call us on 01502 513 122.


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