Traditional Christmas crackers use a gunpowder snap to make the bang. You can't have gunpowder on an airplane.

Jetstar wanted crackers for their in-flight Christmas service, so we had to figure out how to make pulling a cracker apart feel fun without any pyrotechnics. We designed a zig-zag perforation so that when two people pull, the cracker tears into a jagged, satisfying shape instead of just splitting in half.

Inside: custom-written jokes (in-theme for Jetstar, nothing rude), plus a mix of party hats, sunglasses, and other bits. The jokes were the easy part. The perforation took rounds of trial and error to get the tear pattern consistent. Perf is one of those things that either works perfectly or doesn't work at all.