Custom Rigid Boxes
Thick greyboard set-up boxes wrapped in printed or textured paper for a flagship product feel.
- 1.5 to 3 mm greyboard
- Printed or textured paper wrap
- Custom inserts available
In short
Custom rigid boxes are luxury set-up boxes made from thick greyboard wrapped in printed or textured paper, with lift-off, magnetic, drawer or hinged lids. Box Sense makes them to your size from 10 units, with production in 8–12 business days after proof approval. Shipping is free to any address in the USA.
About our custom rigid boxes
A rigid box does not fold flat like a carton. It is built from 1.5 to 3 mm greyboard, wrapped by hand in printed paper or a specialty stock, and arrives as a solid, heavy box that customers keep long after the product is gone. That is why jewelry, electronics, fragrance, spirits and premium gift brands use rigid boxes for their flagship products.
We make rigid boxes to your exact size, with the lid style, wrap, finish and insert your product needs. Short runs start at 10 boxes, which makes rigid packaging realistic for launches, influencer kits and limited editions as well as full retail programs.
Rigid box styles
Choosing the board
| Board | Best for | Notes |
|---|---|---|
| Greyboard 1.5 mm | Small boxes and light products | Lightest option that still feels rigid |
| Greyboard 2 mm | Most rigid boxes | The standard balance of weight and strength |
| Greyboard 2.5 to 3 mm | Large boxes, bottles and electronics | Maximum stiffness for heavier products |
| Printed art paper wrap | Full-color branding | Laminated matte, gloss or soft-touch |
| Specialty textured paper | Luxury and minimalist brands | Linen, leather-look and colored stocks, foil-stamped |
What affects the price of custom rigid boxes
Every box is made to order, so each order is quoted individually. These are the things that move the price most, in order:
- Lid style. Magnetic and drawer boxes cost more than a simple lift-off lid because they have more parts and more hand assembly.
- Inserts. Foam, paperboard or fabric-covered inserts add material and fitting time; multi-cavity inserts cost the most.
- Wrap paper and finishes. Specialty textured papers, foil stamping, embossing and spot UV add to the base cost of printed art paper.
- Size and board thickness. Larger boxes and thicker greyboard use more material and more wrap.
- Quantity. Setup is shared across the run, so the unit price falls as quantity rises, though less steeply than for folding cartons because much of the work is manual.
Send your size, quantity and artwork through the quick quote form for a firm price within 24 hours.
Inserts that present the product
Most rigid boxes include an insert that holds the product in place and frames it when the lid opens. We cut inserts from EVA foam, paperboard or molded pulp, and can cover them in fabric or printed paper. Send us the product, or its exact dimensions, and we engineer the cavity around it.
Finishes that suit rigid packaging
- Hot foil stamping in gold, silver, rose gold and colors
- Embossing and debossing on the lid
- Soft-touch lamination for a velvety feel
- Spot UV to make a logo shine on a matte wrap
- Ribbon pulls, magnetic catches and printed interiors
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 the difference between a rigid box and a folding carton?+
A rigid box is built from thick greyboard wrapped in paper and arrives already assembled. A folding carton is a single sheet of thinner paperboard that ships flat and is folded into shape. Rigid boxes cost more but feel far more premium and are often kept and reused.
What is the minimum order for rigid boxes?+
10 boxes. That makes rigid packaging practical for launches, influencer kits and limited editions.
Do rigid boxes ship flat?+
Standard rigid boxes ship assembled, so they take more space. Collapsible rigid boxes keep the rigid look and feel but fold flat for shipping and storage.
Can you make a magnetic closure rigid box?+
Yes. Magnetic book-style boxes are one of our most popular rigid styles, with the magnets hidden under the wrap.
Can you add a foam insert?+
Yes. We make EVA foam, paperboard and molded pulp inserts cut to your product, optionally covered in fabric or printed paper.
Related products
White Mailer Boxes
Tuck Top Mailer Boxes
Heavy Duty Double Wall Boxes
Custom Product Boxes
Let's build your custom rigid boxes.
Tell us what you are packing. You will have a quote, a free dieline and a sample plan within 24 hours.