A non-lethal projectile carrier includes a base having a plurality of hinges, each hinge including a tab; and a payload case attached to the base, the payload case comprising a plurality of petaloid members, each petaloid member including an opening in a rear surface for insertion of a corresponding tab; wherein upon exiting a gun tube the petaloid members open and fold toward the base. Each petaloid member includes a lip on one edge and an undercut on another edge so that adjacent petaloid members form lap joints. The hinges are defined by zones of small cross-sectional area in the base.