Avery Dennison, the market leader in labels, wanted to offer a smooth and effective method for applying labels to CDs. Prior to their arrival, several competitors were dominating the market with simple yet inferior products that left labels offcenter and lumpy with air bubbles. Avoiding a series of patents filed by several other companies, I designed a solution that combined a flexible plastic applicator with large leaf springs. The springs pulled the plastic into a shape that mimics the curvature of the peeled, adhesive labels.

After a label is placed face down, a CD is pressed down against the label. The applicator flexes downward as the user pushes on the CD, compressing the foam pad and pressing the label from the center outward to remove bubbles. The result is a flat and centered label that makes any CD look professional.

Considerable prototyping was involved with this design. Early rapid prototyping was instrumental in defining appropriate directions to explore further. Both an aluminum injection molding tool and a urethane foam tool were created in order to better understand the ability of certain materials to resist fatigue and properly apply labels.

After the final database was delivered, I continued to support the client through their selection of a manufacturer.