Custom Print & Packaging Design

Bridge the gap between vision and execution.

Where Ideas Become Reality

At Hatteras, our in-house product development team helps clients translate creative vision into expertly engineered pieces ready for production. From secondary packaging and influencer kits, to marketing collateral and direct mail, we offer integrated design services that combine graphic design, structural engineering, and prototyping to enhance your brand.

Whether you’re starting from a concept or fine-tuning an existing layout, we collaborate with your team to create beautiful, brand-aligned designs that are visually compelling, structurally sound, and ready to make an impact. We support every phase of the design process with practical expertise and hands-on production insight. By uniting creative development and technical execution in one place, Hatteras helps your project move faster while maintaining the highest level of quality and consistency.

TYPES OF Design WE OFFER

Graphic Design

Our graphic design services are purpose-built for execution. We design layouts that align with your brand standards and translate seamlessly into finished products.

Visual Layouts & Creative Execution

From postcards and brochures to folding cartons and kits, we create cohesive, brand-driven products.

Brand Integration

We maintain visual continuity across formats and substrates, applying your brand elements with accuracy and care.

User Experience

We design with the consumer journey in mind—creating print-based experiences that are intuitive, elegant, and functional.

Press-Ready Setup

Every file we deliver is preflighted and optimized for production, including dielines, bleeds, color specs, and material considerations.

Structural Design

Process is everything when it comes to bringing ideas to life. Our structural designers create custom solutions for folding cartons, promotional kits, direct mail, influencer mailers, and more—developing pieces that protect, impress, and enhance your brand experience.

Custom Dielines & 3D Mockups

We create detailed dielines and 3D renderings to help visualize structure, folds, and assembly.

Material Selection Guidance

We recommend paper stocks and substrates suited for strength, sustainability, and finish compatibility.

Engineered for the End-Use

Every design is tailored with the final application in mind—accounting for product weight, delivery method, consumer handling, and production requirements to ensure both form and function.

Prototyping & Pre-Production Testing

Seeing is believing, and testing is essential. We prototype your designs to validate how they look, feel, and function before entering production.

Working Prototypes

Evaluate structure, usability, and brand presentation before production begins.

Production-Grade Prototypes

Experience your piece the way your audience will. We craft prototypes using the actual production substrate, so you can confidently approve structure, feel, and function before the full run.

Ship & Stress Testing

Simulate real-world conditions to ensure packaging holds up in transit and arrives intact.

Design Applications Across Industries

Retail & Consumer

POP displays, direct mailers, welcome kits, and packaging that perform at shelf and online.

Pharma & Healthcare

Patient starter kits, collateral kits, dosing guides, and packaging that balances branding with compliance.

Financial Services

Booklets, sales kits, signage, and personalized collateral for high-stakes brand communication.

Beauty & Wellness

Folding cartons, influencer kits, gift sets, and merchandising displays crafted for luxury, clarity, and strong appeal.

Our Collaborative Design Process

From blank canvas to press-ready file, our design workflow keeps projects moving with precision, flexibility, and expertise.

1. Creative Kickoff

We start with a discovery session to understand your objectives, audience, timelines, and production considerations. This includes gathering brand guidelines, exploring creative references & aligning on goals, so we’re set up for on-target work.

2. Concept Development

Our team proposes design directions based on your needs, exploring both structural and graphic solutions that balance creativity, usability, and cost. At this stage, we may present rough mockups, sketches, or inspiration to guide next steps.

3. Design Execution

Once a direction is chosen, we build out final designs. This includes refining layouts, locking in dielines, and preparing files. Our team coordinates directly with production to ensure everything is technically sound and optimized for your materials.

4. Prototyping & Refinement

With the final files in place, we deliver a working prototype or mockup to test how the piece assembles, performs, and presents. This stage gives your team the chance to assess and approve the piece before production—allowing for any adjustments where necessary.

5. Final Production & Fulfillment

Approved designs move directly into production, where all printing, finishing, and fulfillment are managed in-house. With no handoff between design and production teams, we maintain both speed and quality from concept to completion.

A person loads large sheets of printed material into a modern industrial printing press with "PRINT HAPPENS HERE!" displayed on the machine.

A person holds a large printed sheet coming out of an industrial printer inside a factory setting.

A person lifts the cover of a large, complex industrial machine in a well-lit workspace, revealing its internal mechanical components.

Automated machine folding and sorting sheets of paper in a commercial printing or mailing facility.

Integrated Design for Seamless Execution

At Hatteras, design is part of a larger ecosystem. Once your design is finalized, we bring it to life with fully integrated production capabilities, including:

It all happens under one roof at Hatteras.

Designed & Developed by Netwave Interactive

Design