Packaging style
Custom die cut boxes
Any shape, any structure. Our structural designers create custom dielines for unusual products, hexagon boxes, shaped windows and interlocking designs.
Die Cut Boxes in our catalog
3 products use this structure.
Hexagon Boxes
Six-sided boxes that stand out on shelf and stack beautifully for gifting and cosmetics.
Custom Die Cut Boxes
Any structure you can sketch, we can engineer. Free dieline design for shaped and interlocking boxes.
In short
A die cut box is cut from board with a custom die, so it can take a shape or opening that standard box styles do not have, such as a hexagon, a handle or a shaped window. Box Sense makes die cut boxes to your design from 10 boxes.
Every box is die cut in the strict sense. The term is used for boxes where the shape itself is custom: unusual outlines, locking tabs, built-in handles or cut-outs.
If you have a sketch, a sample or a competitor’s box you like, send it. We turn it into a dieline and a sample.
How to specify a die cut box
- Start from the product. Send dimensions and weight; the shape is built around them.
- Sample first. Unusual structures should be tested with an unprinted sample before printing.
- Board. Paperboard or corrugated, depending on weight and how it ships.
- Flat shipping. We design shapes that still ship flat where possible.
Where to start
- Custom Die Cut Boxes: custom shapes and cut-outs.
- Hexagon Boxes: six-sided boxes for gifts and cosmetics.
- Favor Boxes: small shaped boxes for events.
Cost of a custom shape
A custom shape needs its own cutting die, and more complex shapes use more board per box. Simple changes, such as a shaped window or a handle on a standard box, give most of the effect for less.
FAQ
Can you make a box from my own design?+
Yes. Send a sketch, a sample or reference photos, and we create the dieline.
Should I order a sample first?+
For an unusual structure, yes. Samples are available for a small fee.
What is the minimum order?+
10 boxes. Short runs are printed digitally, and larger runs move to offset printing for a lower cost per box.
Ready to make packaging that sells?
Tell us what you are packing. You will have a quote, a free dieline and a sample plan within 24 hours.