Hexagon boxes cause more sizing confusion than any other shape, for one reason: three different numbers can all be called the width. Before you specify a size, decide which one you are quoting, and say so.
The three ways to state a hexagon width
- Side length. The length of one of the six equal panels. This is the number the die is built from.
- Across flats. The distance from one flat panel to the opposite flat panel. It equals the side length multiplied by 1.732.
- Across corners. The distance from one point to the opposite point. It equals exactly twice the side length.
Conversion table
| Side length | Across flats | Across corners | Flat blank width, before glue tab |
|---|---|---|---|
| 2 in | 3.46 in | 4 in | 12 in |
| 2.5 in | 4.33 in | 5 in | 15 in |
| 3 in | 5.20 in | 6 in | 18 in |
| 4 in | 6.93 in | 8 in | 24 in |
| 5 in | 8.66 in | 10 in | 30 in |
Height is independent of all of this and can be whatever your product needs. The blank width column is six panels laid flat, and a glue tab is added on top of it, which is why a wide hexagon uses more board than a square box of the same apparent size.
Fitting a product into a hexagon
The usable interior is set by across flats, not by across corners, because a rigid product has to clear the narrowest crossing. A cylindrical item such as a candle jar fits a hexagon neatly, with the six corners giving room for tissue or filler. A rectangular product wastes space in a hexagon, and if you are packing one, the shape is doing decorative work rather than protective work.
Hexagons do not stack neatly
Six sided boxes do not fill a rectangular shipping carton the way square boxes do. Every hexagon in a shipper leaves triangular gaps at the corners, so plan on void fill or a die cut divider in the outer carton, and expect to fit fewer units per case than an equivalent square box. If you are shipping direct to consumers, put the hexagon inside a mailer rather than sending it as the shipping container.
Lids and closures
- Tuck flaps folded from the panels, the most economical closure and the flattest to ship.
- A separate hexagonal lid that telescopes over the base, used for gift and rigid work.
- A hinged lid on a rigid hexagon, which gives the box a jewelry-case feel.
- A ribbon pull die cut into two opposite panels, common on favor boxes.
Design support is included and will convert whichever measurement you have into a dieline, and the digital proof shows the panel layout before anything prints.
Minimum, price and turnaround
The minimum is 100 boxes. Unit pricing starts at about $0.48 per unit at bulk volumes and is confirmed on your written quote, because a hexagon uses more board and more scores than a rectangular box of similar capacity. The die is included, so a bespoke side length costs no tooling.
Turnaround is stated per product in 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 days for delivery, and specialty imported rigid hexagons can run up to about 12 weeks.
Quote a hexagon box
Tell us the side length or the across flats measurement plus the height on the quote form. See also hexagon boxes for structures and how to choose a box size if you are starting from the product.
