A custom size corrugated box is cut from a die built around your numbers, so the fit is decided by the dimensions you send rather than by whatever stock size happens to be closest. Send inside length, width and depth and the die is made to match. Orders start at 100 boxes, and both the die and the print plates are included in the quote.
How to write a size we can actually cut
Quote inside dimensions, in the order length by width by depth. Length and width are the two sides of the opening, longest side first, and depth is the wall height measured from the opening down. This matters more on corrugated than on any other board because the wall is thick. A size taken from the outside of a sample box loses that thickness on all four sides once it is converted.
Corrugated also has a real manufacturing tolerance. Expect roughly a sixteenth of an inch of variance per dimension on a normal run and design around it. For a rigid product that needs a snug fit, add about an eighth of an inch of clearance per side. If you are adding void fill, a wrap, a printed insert or a bag, measure the product with those in place and send that number instead.
Flute profiles and what each one is for
Flute is the fluted wave glued between the liners. It sets the thickness of the wall, the stacking strength and how smooth the printed surface is.
| Flute | Approximate wall thickness | Typical use |
|---|---|---|
| E | about 1/16 in (1.6 mm) | Retail facing boxes and small products, smoothest print surface |
| B | about 1/8 in (3.2 mm) | General shipping, mailers, food boxes, good flat crush resistance |
| C | about 5/32 in (4 mm) | Larger shipping cartons, more cushioning than B |
| BC double wall | about 9/32 in (7 mm) | Heavy or fragile goods and longer transit |
If the box is going on a shelf as well as through a carrier, E flute prints better and keeps the finished box slimmer. If it is going to be stacked on a pallet or handled repeatedly, step up to C or a double wall and accept the extra wall thickness in your inside dimension.
Printing a made to size box
Because the die is new, the print area is whatever the flat blank gives you, including the flaps and the inside faces if you want them printed. Send artwork built on the dieline rather than on a plain rectangle, keep important type away from scores and creases, and remember that a fold across a heavy ink area will crack more visibly on kraft than on a white liner. Design support is included, so if you only have a logo and a rough sketch, that is enough to start.
What a made to size run costs
The minimum is 100 boxes. Volume pricing starts from about $0.48 per unit at bulk volumes, confirmed on your written quote, since the real figure depends on size, board, ink coverage and finishing. Free US shipping, the cutting die, the plates and design support are all included, and nothing goes on press until you approve a digital proof.
Turnaround is quoted per job across three lanes: rush (expedited production with air freight), standard (air) and cost saver (sea). A straightforward corrugated run starts from about 7 business days in production, plus 2 to 5 days for delivery. Specialty imported constructions can run up to about 12 weeks, so get the lane confirmed in writing before you plan a launch date around it.
Send your dimensions
If you already have the numbers, put them straight into a quote request with the quantity and we will come back with a price and a lane. If you are still deciding on board or size, read corrugated box dimensions and what flute means in corrugated first, or start from the standard corrugated boxes range and tell us what you would change.
