Key takeaways
- Measure the product and decide what ships together.
- Mailers suit e-commerce; slotted cartons suit bulk shipping.
- Pick board strength based on weight and fragility.
- Use inserts instead of oversized boxes.
- Drop-test samples before ordering in volume.
Step 1: Measure your product
Measure length, width and height at the largest points, including caps, handles and accessories, and weigh the product. Decide whether one item or several will ship together, and whether you will include extras such as a card, sample or instructions.
Step 2: Choose the box style
The most common shipping styles:
| Style | Best for |
|---|---|
| Mailer box (roll end tuck front) | E-commerce, subscriptions, gifts |
| Regular slotted carton (RSC) | Bulk shipping, heavy items, wholesale |
| Rigid mailer | Flat items such as prints and documents |
| Tray and sleeve | Premium shipments |
| Shipping box with inserts | Fragile or multi-item orders |
Step 3: Choose the board
E-flute single-wall corrugated is ideal for light mailers and prints well. B-flute adds cushioning for heavier items. Double-wall board such as BC flute suits heavy or fragile goods. If boxes will be stacked in warehouses, ask about edge crush test (ECT) ratings.
Step 4: Plan the inside
Use custom inserts, dividers or padding so products cannot move. Think about the order in which the customer will see items, and where a thank-you card or instructions will sit. A well-organised interior protects products and improves the unboxing.
Step 5: Design the artwork
Place your logo where it is seen first, usually the lid of a mailer. Leave space for shipping labels and any handling marks. A printed interior creates a memorable reveal at relatively low cost.
Step 6: Proof, sample and test
Approve the dieline and a 3D mockup, then order a physical sample. Pack it with your real product and drop it from waist height onto each face, edge and corner. If anything moves or breaks, improve the insert or upgrade the board before ordering in volume.
Making a box by hand
For a prototype, draw the box net on a corrugated sheet, score fold lines with a blunt tool, cut with a sharp craft knife and tape the seams. It is useful for testing size, but hand-made boxes are slow and rarely as strong or neat as die-cut boxes.
Costs to expect
Price depends on size, board, printing coverage, finishes, inserts and quantity. Larger orders lower the unit price. Ask for quotes at two or three quantities to see where the price breaks fall.
Frequently asked questions
How do I make custom shipping boxes?
Measure, choose a style and board, design artwork, approve a mockup, test a sample and order.
What is the cheapest shipping box?
A single-wall regular slotted carton.
Can I make shipping boxes myself?
For prototypes yes; for volume a supplier is faster and stronger.
What is the minimum order?
With us, from [100] units for most styles.