Greyboard, sometimes called chipboard or carton board in different markets, is the stiff grey sheet you feel underneath a rigid box, a hardback cover or a game box lid. It is made largely from recycled fibre, pressed dense, and it is a structural material rather than a printing surface. That last point is what makes rigid packaging work the way it does.
What it is and what it is not
Greyboard is not folding carton board. A folding carton is printed, cut, creased and folded from a single sheet, and the printed surface is the board itself. Greyboard is cut into panels, assembled into a box shape, and then wrapped in a separately printed paper. That is why a rigid box has no creases on its outside faces and why the print quality is a property of the wrap, not of the board.
How thickness is specified
Greyboard is ordered by thickness in millimetres. Rigid box work commonly falls between about 1.5 mm and 3 mm, and the choice is a feel decision as much as a strength one.
| Thicker board | Thinner board |
|---|---|
| Feels more substantial in the hand | Feels lighter, closer to a carton |
| Larger external size for the same cavity | Smaller external size, better freight cube |
| Holds sharp corners under handling | Corners soften faster with handling |
| More material per box | Less material per box |
The sizing consequence people miss
Because greyboard is a core with a wrap over it, the outside of a rigid box is always bigger than the inside by twice the board thickness plus the wrap on each axis. On a two piece box, the lid adds another layer over the base. A cavity sized to 100 mm across does not produce a 100 mm box, and if you are fitting that box into a shelf, a shipper or a mailer, you need the external number. Always confirm on your quote which dimension is being stated.
Where greyboard is used
- Two piece rigid setup boxes and magnetic closure boxes.
- Game boxes, where the lid has to survive repeated opening.
- Drawer and slipcase style boxes.
- Book covers and presentation folders.
- Backer panels and dividers inside heavier packaging.
Recycled content and appearance
The grey colour comes from mixed recycled fibre, which is also why greyboard is always wrapped or lined when appearance matters. If you want an exposed board look, that is achieved with a different board choice or a printed liner, not by leaving greyboard bare, since the raw surface marks easily. For the rigid formats we build, see rigid boxes, and for a comparison against folding cartons see rigid versus folding carton.
Ordering and turnaround
Rigid boxes over greyboard start at a 100 unit minimum, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before printing are included. We produce in West Chicago in the US and in Guangzhou in China. Three lanes are quoted per product: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days in production plus 2 to 5 days for delivery, and specialty imported rigid work can run up to about 12 weeks because the assembly is hand finished.
Tell us your cavity size and the feel you want and we will recommend a board thickness and confirm the external dimensions. Request a quote to start.
