Box 1.0

I designed, drew up the model and created a mockup of the wallet.  The measurements are skewed to allow the tag inside the wallet (this was intentional so that it would add body and have my contact info). The template was designed on drawing paper, so it's pretty thin. I think I'll make the actual boxes out of bristol board or a similar card stock. The x's are all parts that should be cut out.

Box Template 6 4/8'' x 12''

With the template cut out and tabs made (this will need refining), I ended up using tape. Ultimately I'll use glue or another adhesive that won't show.

Box fully assembled.

I wanted the box to fit snug but still have some space in case the gifter wanted to have tissue paper to gussy it up a bit.  The wallet can lay flatter but it naturally bulges out. The card insert gives it body and also contains my email address and website link.

Box with wallet and card insert.

Designing Methodology

When I design I usually start super simple: What do I want to make. By this time, I basically know my aesthetic so I know how I want whatever I'm making will look but the various elements can be pretty complicated.

If I wanted to make a bag, I want to know what kind of bag it'll be, what kinds of enclosures I want, how the bag will be held or carried and pockets. Don't forget the pockets.  I'll usually have an idea about the dimensions and from there I break down each sewable element such as which step needs to follow the previous step, measuring panels with seam allowances, etc.  Often I'll look online for how construction works, the materials needed, and over the course of a few hours to a few weeks, I will spend designing how I want this bag to look and how I'd assemble it.

I have a fairly tame aesthetic and tend to want as simple a design as possible, since I don't work with a lot of exotic materials/tools.  Also I find that busy designs are needlessly complicated and there are often too many ways things could go to hell.  Remember KISS: Keep It Simple Stupid.