Die cut boxes are made by pressing board through a custom cutting die, which allows shapes, tabs and features that a standard scored box cannot achieve. That opens the door to self-locking closures, unusual profiles and integrated inserts, all cut in one pass rather than assembled from parts.
Balancing shape and strength
A distinctive shape can weaken a box if too much board is removed or folds fall in the wrong places. The design has to keep enough structure to protect the contents and hold up through handling, so it is worth balancing the visual idea against how the box will actually perform when packed.
Fit and finishing
A die-cut design is easier to judge in the hand than on screen.
- Keep enough board for the box to hold its shape
- Design any locking tabs to close reliably
- Size the interior for a secure fit
Ordering and proofing
A bespoke die is made once and then reused, so it pays to confirm the shape works before it is cut. A flat proof or a made-up prototype shows how the tabs lock and how the box holds its shape when packed. Set out the product, the effect you are after and how the box is handled when you request a quote, so the design can be planned realistically.
These boxes are made to your custom size. Because a bespoke die shape is hard to picture flat, a sample or prototype is a sensible step before production.
