Custom box design
Packaging designed around your product, then built by the right line
Structural design, dielines, 3D mockups and physical samples for corrugated, folding-carton and rigid boxes. We know which partner plant in Vietnam can make each design well, so the box you approve is a box that can be produced on time and on budget.
What the design service covers
Structural design
Choosing or adapting a standard style (FEFCO, tuck-end, rigid) or creating a new structure, sized to the product with the right clearances, closures and inserts.
Dielines (cutting & crease drawings)
Production-ready dielines in PDF / AI with cut, crease, perforation and glue areas marked, plus bleed and safe zones for your designer to place artwork.
3D mockups
Your artwork applied to the folded box on screen, so you can check how panels, flaps and logos line up before anything is cut.
Plain (white) samples
Unprinted prototypes cut on a CAD sample table, with no cutting-die cost, to test fit, strength and how fast the box folds up.
Printed prototypes
Short digital print on the real board (HP Indigo for paperboard, inkjet for corrugated) for photo shoots, investor or retailer presentations and colour sign-off.
Artwork preflight
We check files against the dieline: colour mode, resolution, bleed, fonts, Pantone references, white ink on kraft or metallic board, and barcode placement.
How a custom box project runs
- 01
Brief
Product size and weight, how fragile it is, how it travels (courier, pallet, shelf), target quantity, budget per unit, timeline and the look you want.
- 02
Concepts & material proposal
One to three structural options from our style library or a new design, each with a recommended board, print method and the partner line best suited to make it.
- 03
Dieline & 3D mockup
You receive the dieline for artwork and a 3D preview. Your designer places artwork, or we coordinate with one.
- 04
Sample & test
A plain sample to check fit and assembly, then a printed prototype if needed. We adjust dimensions, flaps or inserts until it works.
- 05
Sign-off
You approve the final dieline, artwork proof and colour standard. These become the reference for production and for every repeat order.
- 06
Production handover
We hand the approved spec to the partner plant, follow tooling and press checks, and run a final inspection before delivery.
What to send us
- Product dimensions (L × W × H) and weight, or a sample of the product
- How many products per box, and whether you need an insert
- How it ships and sells: courier, pallet, export, retail shelf, gift
- Quantity for the first order and expected repeat volume
- Logo, brand colours (Pantone if you have them), any reference boxes you like
- Target delivery date and delivery city
Artwork checklist for boxes
- Build artwork on our dieline, keeping the dieline on its own layer
- CMYK (plus Pantone spot colours where needed); PDF/X-4 preferred
- 3 mm bleed past cut lines; keep text 3–5 mm away from folds and cuts
- Images at 300 dpi at final size; fonts outlined or embedded
- On kraft or metallic board, mark any white ink areas on a separate layer
- Mark foil, spot UV and emboss areas as separate spot layers
What we design for
Right size
A box that fits closely needs less void fill, protects better and costs less to ship, because couriers charge by volumetric weight.
Right board
Strong enough for the route and stack height, and no stronger. Over-specifying board is one of the most common hidden costs in packaging.
Fast to pack
Self-locking and ready-glued styles cut packing time. We consider who folds the box, how many per day and whether a machine is involved.
Print that suits the run
Digital for short runs and many versions, offset for high-graphic volume, flexo for economical shipping cartons. The design is set up for the method chosen.
Less plastic
Paper inserts and dividers in place of foam where they protect well enough, so the whole pack can go in one recycling stream.
Box design questions
Do I need a designer before I contact you?
No. Send the product details and we start from structure. When it is time for graphics, your own designer can work on our dieline, or we can connect you with one.
Is there a charge for design and samples?
It depends on the project. Any design, sampling or prototype cost is quoted and agreed with you before work starts, so there are no surprises.
Can I get a printed sample before ordering?
Yes. For most folding cartons and corrugated mailers we can produce a short digital print on the actual board. Offset and flexo colour can differ slightly from a digital proof, so we agree a colour standard at sign-off.
How long does design take?
A standard style adapted to your size is usually a few working days to dieline and plain sample. New structures or multi-part inserts take longer and may need more than one sample round.
Who owns the dieline and the cutting die?
The approved dieline is yours. Cutting dies are made for your job and kept for repeat orders; we confirm the arrangement for each job in the quote.
Tell us about your box
Share the product, quantity and how it ships. We reply with style options, materials and a quote, usually within one working day.