Custom packaging by structure
Pick the structure. We cut it to your size.
Custom packaging starts from the product, not from a catalog. Rigid boxes, folding cartons, mailer boxes and corrugated boxes each do a different job, and the right one depends on what is inside, how it is sold and how it travels. Here is how to choose, and where inserts, print and finishing come in. Every structure is made to your dimensions from 50 boxes.
Every family is made to your product’s dimensions rather than selected from stock sizes. Start from the structure that fits how the product ships and sells.
Packaging families
Also:Custom Inserts
Boxes by style
Or start from the style you have in mind.
Most buyers know how the box should look and open before they know which family it belongs to. Pick the style; we cut it to your dimensions.
All styles
How to choose
How to choose a packaging family.
Rigid box, folding carton, mailer or corrugated
A rigid box is wrapped greyboard that holds its shape. A folding carton is one sheet of paperboard, die-cut, scored and glued, shipped flat and printed edge to edge. A mailer box is self-locking corrugated, built to survive a courier. A corrugated box is fluted board specified to the load. Weight, fragility and how the product is sold decide which.
Protection or presentation
Most products need both. Presentation is the surface: the print, the finish, the way a lid lifts or a tray slides out. Protection is the board gauge, the insert and how the closure holds. A carton with an insert protects a bottle well; a rigid box does both; a mailer protects first and presents when it opens.
Dimensions decide the box
We work from the product's length, width and depth and build outward, so the inside fits what goes in it rather than leaving a void. Clearance for an insert, a lid or an irregular product is added on the dieline. The measurements, or the product itself, are enough.
Inserts hold the product still
An insert turns a box into packaging. Die-cut board, foam, moulded pulp and fabric-wrapped inserts are cut to the product's footprint, so nothing rattles and the product is presented as the box opens. Inserts are drawn into the dieline with the box they sit in.
Quantities
The minimum order is fifty boxes on every structure. Unit cost falls as the quantity rises, because setup and the die are spread across more boxes, and there are no die charges on any order. Quote at two or three quantities and the difference is shown in writing.
Compare
The four families compared.
| Rigid box | Folding carton | Mailer box | Corrugated box | |
|---|---|---|---|---|
| Construction | Wrapped greyboard, assembled | One sheet of paperboard, die-cut and glued | Self-locking corrugated, usually E-flute | Fluted board: E, B or double wall |
| Ships | Assembled | Flat | Flat, folds by hand | Flat |
| Feel | Heavy, hard-edged | Light and crisp | Sturdy, practical | Robust |
| Print surface | Printed or specialty wrap paper | Coated board, full color edge to edge | Liner: flexo or litho-lam, inside and out | Liner: flexo, litho-lam or digital |
| Protection | High | Light to moderate | Good through parcel networks | Highest |
| Typical use | Gifts, jewelry, fragrance, sets | Cosmetics, supplements, food, retail shelf | E-commerce and subscription | Heavier products, multi-packs |
In detail
Print, finish and style.
Printing and finishes
Cartons and rigid box wraps print full color CMYK or Pantone; corrugated prints single color by flexo or full color by litho-lamination; kraft suits single color, white ink or foil. Lamination is included on every order, and foil stamping, embossing, debossing, spot UV and window patching are added where the artwork calls for them.
Boxes by Style
Once the family is settled, the closure is next: magnetic, lid and base, drawer, reverse tuck, auto-lock, roll-end tuck top and the rest. Boxes by Style covers each construction, what it suits and what to specify for a quote.
Packaging questions
Before you ask.
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhich packaging family should I choose?
Rigid boxes for weight and presentation, folding cartons for the shelf, mailer boxes for anything that travels to a customer's door, corrugated for heavier or fragile products. If in doubt, send the dimensions and a photo.
What is the minimum order for custom boxes?
50 boxes, on every structure. Unit cost falls as the quantity rises.
How long does production take?
Approximately 10–12 working days from proof approval and payment. Ground shipping adds 3–5 working days, and delivery is free on every order to US addresses.
Can I see a sample before the full run?
Standalone samples are chargeable, because one or a few boxes need the same setup and production procedures as the full job. On a qualifying bulk production order, once the order is placed, a pre-production sample may be produced for approval at no additional sample charge; after approval the remaining quantity proceeds.
Start a quote
Three answers is all it takes to open a job.
Structure, board and finishing come next — with our team, on the full quote form.
No account needed. Artwork and reference images can be attached on the next step.
Start here
Send us your dimensions. We’ll send back a box.
Or talk to a packaging specialist: (209) 444-0744