Die cutting is how nearly every custom box gets its shape. A steel rule die, essentially a plywood board with sharpened steel blades set into it, presses through the printed sheet and cuts the outline, the tabs and the score lines in one pass. Because the die is built for your box, a custom size costs the same per unit as a common one. Ready to order rather than research? The die cut boxes product page is where you configure and buy.
What the die actually is, and who pays for it
In most of the industry the die is a one-time tooling charge on your first order. At iBox the die and the plates are included, which changes two decisions. First, you can size the box to the product instead of squeezing the product into a size someone else already tooled. Second, a reorder of the same box has no tooling line on it at all, so reruns stay clean.
Die cut styles buyers ask for most
| Style | How it closes | Usually chosen for |
|---|---|---|
| Straight tuck end | Both flaps tuck from the same direction | Retail cartons where the front panel must stay clean |
| Reverse tuck end | Flaps tuck from opposite directions | Everyday cartons, the most economical layout on the sheet |
| Auto bottom | Base locks itself when the box is squared up | Heavier contents and faster hand packing |
| Roll end tuck top mailer | Front tab tucks into a slot, no tape needed | Ecommerce shipping and unboxing |
| Two piece lid and base | Separate lid lifts off | Rigid presentation packaging |
What your dieline needs before it can be cut
- Vector artwork, not a flattened image, so the cut and crease paths stay crisp.
- Cut, crease and perforation paths kept on separate layers and labeled.
- Bleed carried past every cut edge, because sheets shift slightly in the press.
- Fonts outlined or supplied, so type does not reflow on our end.
- Type and logos held back from creases, since print distorts where board folds.
If you do not have a dieline, design support is included and we will build one from your product dimensions. Our starting point at what a dieline is explains how to read the file we send back.
Materials that die cut cleanly
Folding carton board takes the finest detail and holds intricate cuts such as windows, handles and locking tabs. Corrugated cuts well too, though very fine detail softens because the flute underneath is not solid. Kraft board cuts the same as bleached board, it just carries a brown surface. Rigid chipboard is not die cut in the same pass, it is cut and then wrapped, which is why rigid work runs longer.
Cost, minimum and lead time
The minimum is 100 boxes. Unit pricing starts at about $0.48 per unit at bulk volumes and is confirmed on your quote, since size, board, coverage and finish all move it. Turnaround is stated per product across three lanes: Rush (expedited production plus air freight), Standard (air) and Cost saver (sea). Production runs from about 7 business days plus 2 to 5 for delivery, while specialty imported items can reach about 12 weeks.
Next step
Send dimensions, quantity and artwork through the quote form for a written price, or read whether custom boxes need a plate if the tooling question is what is holding you up.
