Good packaging does three things: it fits, it protects and it tells the customer who made the product. Our custom double wall cardboard boxes are built around those three jobs. Sizes are set from your product’s measurements, the material is matched to its weight and how it will be sold, and the print carries your branding on every panel you want to use. Here is what you can choose from.
Who uses custom double wall cardboard boxes
Custom Double Wall Cardboard Boxes are used mainly by retail brands, online sellers and small businesses. Some customers need a few hundred units for a market stall or a product test, others need regular production runs for retail and wholesale accounts. In both cases the questions are the same. What is the product’s size and weight? Will it sit on a shelf, go in a shipping carton or be handed over a counter? Does it need to be seen through a window, kept away from light or held still by an insert? Your answers decide the specification, and we are happy to suggest one if you are unsure.
Materials
The material sets the strength, the feel and the print quality of the finished box. These are the options we use most for custom double wall cardboard boxes.
- SBS cardstock (14pt to 24pt). The all-round folding carton board with a smooth white print surface.
- Kraft board. Brown, recyclable and strong for its weight.
- Corrugated E-flute. Adds crush resistance for heavier items and displays.
- Rigid board. For premium presentation boxes that are kept and reused.
Styles and structure
The structure you pick affects how the pack opens, how much weight it carries and how fast it can be filled. Common options for custom double wall cardboard boxes include straight tuck end, reverse tuck end, auto-lock bottom, snap-lock bottom, sleeve and window box. Simple tuck-style and fold-over closures are quick to assemble by hand and cost the least. Locking bases, inserts and two-piece or magnetic constructions add strength and presentation value. If you have a sample of packaging you like, send a photo and the measurements and we can work from that.
Printing and finishes
Artwork is printed in CMYK, with Pantone spot colors available for exact brand matches. You can print one side or both. A protective coating follows: gloss for brighter color, matte for a flat, glare-free look, or soft-touch for a smooth, velvet-like surface. For more impact you can add metallic foil, embossing or debossing, or spot UV on chosen areas. These are optional. A clean design on good material with a single well-chosen finish usually looks better than several effects competing on one panel.
Sizes
There is no fixed size list for custom double wall cardboard boxes; every order is cut to the dimensions you supply. The table shows common starting points so you can see what is typical. Use it as a reference, then measure your own product, because containers and products with the same stated capacity often differ by several millimetres.
| Size | Typical dimensions | Used for |
|---|---|---|
| Small | 2 x 2 x 2 in | jewellery, samples, small accessories |
| Small tall | 2 x 2 x 5 in | bottles, tubes |
| Medium | 4 x 4 x 4 in | candles, mugs, gifts |
| Medium flat | 6 x 4 x 2 in | accessories, soap sets |
| Large | 8 x 6 x 4 in | apparel accessories, kits |
| Extra large | 12 x 9 x 4 in | clothing, bundles |
What to check before you order
The right structure depends on weight and how the box is handled. Light items do well in tuck-end cartons; heavier ones need an auto-lock or snap-lock bottom so the base does not open when the box is lifted.
Custom packaging is worth the effort because small details add up. A pack that fits closely needs less filler and costs less to ship. A panel that states clearly what the product is reduces questions and returns. A consistent look across your range makes each product easier to find the next time a customer shops. None of this requires an expensive specification, only one that has been thought through.
Artwork
For the best print result, supply artwork as a vector PDF, AI or EPS file with fonts outlined and images at 300 dpi or higher. Add 0.125 in of bleed beyond every cut line and keep text at least 0.125 in inside it, so that small movements during cutting do not leave white edges or trim your text. If you do not have a dieline, we will send one in the correct size for your designer to work on.
How ordering works
Ordering is straightforward. Send us the size, quantity, material and any finishes you want, along with your artwork if it is ready. We reply with a quote. Once you approve it, we prepare a dieline, which is the flat template of your box, and place your artwork on it. You receive a digital proof showing every panel, fold and cut. Nothing is printed until you approve that proof, so check spelling, colors, barcodes and required text carefully. Unit price depends mostly on quantity, size, material and finishes, and it falls as quantity rises because setup costs are shared across more pieces. Minimum quantities and production time vary with the specification, so ask about both when you request your quote.
Questions about custom double wall cardboard boxes
Will I see a proof before printing?
Yes. You receive a digital proof on the dieline showing all panels. Production starts only after you approve it.
How long does production take?
Lead time depends on quantity, structure and finishes such as foil or embossing. We confirm the schedule with your quote, and the clock starts when you approve the proof.
Are there eco-friendly options?
Yes. Kraft and recycled materials, water-based coatings and plastic-free structures are available for most products. Ask for these when you request a quote.
Is there a minimum order quantity?
Minimums depend on the material, size and print method. Tell us the quantity you have in mind when you request a quote and we will confirm what is possible.
What sizes do custom double wall cardboard boxes come in?
Any size. Each order is made to the length, width and height you give us. The size table on this page shows common dimensions, but your own product’s measurements should decide the final size.