Conventional box formats inevitably result in a conflict between brands: They have to either purchase large boxes that use board and packing materials that they do not need or choose cartons that don't fit the product at all. Both routes waste money and create an excess of cardboard, foam and void-fill that goes to waste in the trash. To address this, custom die cut boxes are formed around the product, eliminating dead space to fill and no material that is cut away and thrown out. In the face of brands that need to reduce expenses and reduce waste in the same breath, die cut carton packaging is the answer for them.

Custom Die Cut Boxes: What They Are?

Specialty packaging boxes are cartons that have been cut and scored to a specific shape and design, as opposed to being based on a standard template, and using a steel die that has been made specifically for that product. This is one type of specialty packaging boxes that can be made to have window openings, cutouts, dividers or internal locking tabs in one board with no expensive tape, inserts or glue to keep the box in place.

 Why are brands making the switch to die cut packaging?

• Less material waste (no wasteful board or die to cut down a generic carton, no void fill, no oversized cartridge die cut).

• Reduced shipping cost: A box that fits the product will be lighter and will pack more, reducing freight cost per unit.

• Better brand presentations: Custom box shapes with cut-outs, windows or locking flaps are perceived as high quality and thoughtful, rather than standard.

• No materials added to maintain structural integrity: Locking tabs and fold patterns maintain the product's integrity without foam or plastic inserts.

• By design: Single material printed die cut boxes are easier to recycle than boxes with mixed foam, plastic and cardboard materials.

Features & Specifications

• Sheet size: standard 40" x 48" or any other size available.

• GSM/Board Weight: light for retail cartons and heavy for shipping grades die cut boxes.

• Printing: Offset or digital print, full CMYK, Pantone colour matching.

• Sizes & Shapes: Fully custom: hexagons, sleeves, trays, window boxes or product specific silhouettes.

• Finishes include matte or gloss lamination, spot UV, foil stamping and embossing.

• MOQ: Smaller brands can test a shape before a full production run of some standard die shapes.

Custom Die Cut Packaging Applications

Whether it's an electronics accessory, cosmetics, food or a subscription product, custom boxes shapes are ideal for retail packaging that requires a tight fit and protects the product. E-commerce brands are relying on die cut mailers to reduce dimensional shipping weight. Die cut inserts and risers can be used to create a shelf ready display presentation that culminates with trade show and retail display teams. Any product with an irregular shape, delicate or in-season shipment in an oversized stock box is a potential die-cast.

The key points to consider are:

Request a physical , die cut carton packaging sample, rather than a flat proof on screen: what looks good on screen may not fold or lock well in hand. Verify that the board weight is the same as the product's shipping weight: not its retail weight. The biggest mistake that brands can make is creating a shape of their die based on the product rather than testing it with the actual carton where they intend to put it. The second is not running a structural test print before making a print order, or committing to a print order, which is the most common time scoring tabs or score lines need adjustment.

The reasons for choosing Custom Boxes Manufacturer 

Custom Boxes Manufacturer is able to design and cut dies in-house, so if you want to change the shape, it's not a problem with a new vendor. Made and shipped quickly, across the USA, Free Design, No minimum orders for most shapes, Wholesale prices for repeat orders, and Eco Friendly board choices all included in every order.

FAQs

Q: Are custom die cut boxes more expensive than normal boxes? 

A: Upfront cost for the dies is one-time only, but shipping and material savings will generally even out the cost after just a couple of runs.

Q: Is it possible for a die cut box to be recycled? 

A: Yes, single material corrugated or kraft die cut boxes with no foam or plastic inserts are 100% recyclable.

Looking to cut waste out of your packaging

Mock up your design for free and get a wholesale quote for a die shape created for your exact design. Call: 713-978-0088 Email: sales@customboxesmanufacturer.com.