At Zappiebox, we believe every child is a creator. Our mission is to challenge, inspire, and above all, let children aged 5 to 9 have fun, without screens, but with their hands. But how are our boxes actually created? How do we ensure that every Zappiebox is not only educational but also fun, achievable, and safe for children?
In this blog post, we'll take you behind the scenes, from initial idea to production. Because yes, all our boxes are designed and tested in-house, together with our dedicated team of product designers: Sebastiaan and Job.
1. It starts with getting ideas
Every box starts with an idea. Sometimes it stems from something we enjoyed building ourselves as a child, sometimes from a scientific or technological principle we want to teach children. Think of motion, gears, magnetism, or light.
At the beginning of each month, we organize a brainstorming session where we all—Joep, Jimmy, Sebastiaan, and Job—come up with tons of fun ideas. We ask ourselves: what's fun and educational? But also: what's appropriate for the age group and feasible to implement?
We're documenting everything in a comprehensive list of potential projects. Some quickly disappear into the trash, while others are so exciting that we move them on to the next phase.
2. From idea to concept design
The ideas that stick are developed into an initial concept. Job and Sebastiaan create sketches and design components in 3D software. Here, we consider not only the form but also how it works.
We always take the following into account:
- Educational value : what do children really learn from this?
- Playability: Is it fun to do?
- Motor skills: young children can easily put the parts together
We 3D-print or laser-cut the parts we want to test. Sometimes we build multiple versions of the same design to test different approaches.
3. First prototypes: testing, fitting, feeling
Time to build! We're making the first prototypes on our own laser cutter. This allows us to quickly cut components from wood or cardboard. This is the perfect time to test whether everything fits, is sturdy enough, and feels logical.
We pay attention to the following:
- Does the construction work as intended?
- Are there smart connections or should it be simpler?
- Does it feel sturdy in a child's hands?
The fun part about this phase? It's really great when a project suddenly comes to life.
4. Improve and retest
After the first prototype, we go back to the drawing board. We make adjustments based on our findings. Sometimes something turns out to be too difficult, or too easy. Sometimes we see that parts could be improved or simplified. And sometimes we decide to revamp the entire concept.
We often repeat this phase several times. Our goal: a building experience that's challenging, yet achievable for a child between 5 and 9 years old, without requiring much parental assistance.
5. Creating the instruction booklet
Once the prototype is working, an equally important part of the process begins: creating the instruction booklet. At Zappie, we believe children should be able to build as independently as possible. This requires clear, visual explanations.
Our instruction booklets are designed with a mix of images and text, with the image always being the primary focus. Each project is illustrated step by step in our signature style, so even young children (who may not yet be able to read properly) can work independently.
We also ensure that each step visually aligns with the actual components and that the manual evolves with the complexity of the project. In our experience, a good manual makes the difference between frustration and pride.
Before an instruction booklet is finalized, we present it to a group of test children (and their parents). We use their feedback to refine the text or visuals. We continue to refine everything until everything is crystal clear, even if that takes ten versions.
6. Testing with children (at school or after-school care)
Once the prototype and booklet are ready, we'll test the box with real children. We'll do this at primary schools or after-school centers, where we'll organize a test afternoon.
Here is what we pay attention to:
- Do they understand it without help?
- Where are they stuck?
- What do they like most?
- Is the end result sturdy enough to play with?
We record everything during the testing process (with permission, of course) so we can thoroughly discuss what went well and what didn't. This testing phase is often the most surprising: children sometimes use a design in a completely different way than we had envisioned.
7. Final fine-tuning & customer feedback
After the test session, we incorporate the final improvements. Sometimes we change components, sometimes we rewrite an instruction step. Only when everything is perfect do we send the box to a small group of customers: a kind of "pilot customer" selected based on experience with previous boxes.
They provide feedback on:
- The level of difficulty
- Comprehensibility of the booklet
- Their child's experience
- Any errors or ambiguities
We take this feedback seriously. A Zappiebox only goes into production when we hear from everyone: "Yes, this works."
8. Ready for production
Once the box has been tested, improved, and approved, it goes into production! We order all the materials, have the booklet professionally printed, and package everything into one complete Zappiebox. Then it's included in our monthly shipping round.
And then the fun begins: photos of proud children who've built their own microscope, airplane shooter, or spinning wheel. That's what we do it for.
Finally
Every Zappiebox is the result of months of work, lots of love, and endless testing. We design everything ourselves because we believe that's the only way to create the best product, one that truly benefits children.
Do you have any questions about how we work? Or ideas for our next box? Let us know!