Custom Die Cut Boxes
Any structure you can sketch, we can engineer. Free dieline design for shaped and interlocking boxes.
- Any shape or structure
- Free structural design
- Sample before production
In short
Custom die cut boxes are boxes cut from a single sheet with a custom-made cutting die, which allows any shape, fold pattern, window, handle or locking tab your product needs. Box Sense makes them from 10 boxes, with production in 8–12 business days after proof approval. Shipping is free to any address in the USA.
About our custom die cut boxes
Every box is die cut in some sense, but a custom die cut box is one designed from scratch for a product that standard styles do not fit: unusual shapes, built-in handles, locking tabs, inserts formed from the same sheet, or a structure that is part of the brand.
Our structural designers build the dieline around your product and send a sample to test. Design is free, and orders start at 10 boxes.
What custom die cutting makes possible
Choosing the board
| Board | Best for | Notes |
|---|---|---|
| SBS paperboard, 14 to 24 pt | Most retail cartons | Bright white for sharp print |
| Kraft paperboard | Natural and eco brands | Brown fiber look; dark inks or white ink |
| E-flute corrugated | Heavier products and shipping | Thin corrugated with a smooth print face |
| Rigid greyboard with wrap | Premium and gift versions | Heavy, solid feel |
What affects the price of custom die cut boxes
Every box is made to order, so each order is quoted individually. These are the things that move the price most, in order:
- Complexity. More folds, cut-outs and glue points mean more die-making and finishing time.
- Board. Paperboard, corrugated and rigid board are priced differently.
- Sheet usage. Unusual shapes can waste more board per sheet.
- Quantity. The unit price falls steeply as quantity rises; short runs can be digitally cut without a die.
Send your size, quantity and artwork through the quick quote form for a firm price within 24 hours.
From sketch to sample
- Send product dimensions, photos or a sketch
- We design the structure and a flat dieline
- You receive a 3D proof and, if you wish, a physical sample
- After approval, the cutting die is made and production begins
No die charge on short runs
Short runs are cut digitally, with no physical die to pay for, which makes custom structures affordable from 10 boxes. Larger runs use a steel-rule die for speed and the lowest unit price.
How ordering works
- Send your specs. Product size, quantity and artwork (or just a logo). A packaging specialist replies with a firm quote within 24 hours.
- Approve the proof. We send a dieline and a 3D proof so you can see the box before it is made.
- Production. 8–12 business days in our own facility, or 5 days on rush.
- Delivery. Boxes ship flat to you anywhere in the USA, free of charge.
Frequently asked questions
What is a die cut box?+
A box cut and creased from a flat sheet using a custom cutting die, so it can take any shape or structure.
Do I have to pay for the die?+
Not on short runs, which are cut digitally. Our quotes include tooling.
Can you design the structure for me?+
Yes. Structural design and the dieline are free.
What is the minimum order?+
10 boxes.
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Let's build your custom die cut boxes.
Tell us what you are packing. You will have a quote, a free dieline and a sample plan within 24 hours.