Custom Booklet Rigid Boxes
Custom booklet rigid boxes that open like a book — a hinged cover over a rigid tray with an insert, closing on a magnet — wrapped and foil-stamped to your brand from 100. Dieline and price the same working day.
A box that opens like a book and closes like one
- Board
- Grayboard 2 mm covers; 1.5–2 mm tray
- Builds
- Hinged cover over fixed tray; magnetic or ribbon close
- Insert
- Die-cut board, foam or pulp to the product
Get a price for Booklet Rigid Boxes
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Anatomy of a booklet box
| Cover | A hardback case — front, spine, back — wrapped in one sheet |
|---|---|
| Tray | A rigid tray glued to the inside of the back cover; holds the insert |
| Insert | Die-cut board, foam or pulp cut to the product |
| Closure | Magnets in the front cover and the tray wall; or a ribbon tie |
| Inside front cover | A printed page: the message, the story, the instructions |
Products that suit a book box
Our rigid boxes across every construction cover the lidded and drawer versions.
- Cosmetics and skincare sets — the tray holds each piece, the cover explains the routine.
- Tech accessories and small electronics — a cradle in the tray, the cover as the manual.
- Spirits miniatures, chocolates, tea selections.
- Corporate and luxury gifts with a printed message inside the cover.
- Product samples and press kits.
The hinge, and why it is the hard part
A book box is opened and closed many times, and the hinge is the wrap paper at the spine. It is built with a gap between the cover boards sized to the tray depth, so the cover closes flat without straining the paper, and the wrap at the spine is reinforced on deeper boxes. A hinge built too tight cracks the wrap in a month.
Tray depth sets the spine width. Send the product; the spine is drawn from the insert depth, not guessed.
Wrap, foil and the spine
A book box is wrapped in a single sheet — printed paper, linen, soft-touch, leather-grain — with the front cover and spine foil-stamped like a book. The spine is what shows on a shelf, so it carries the brand as a book carries its title. Inside, the front cover is a printed page and the tray liner is a color.
Sizes, runs and shipping
From A6 to A4 covers with trays 20–60 mm deep. Book boxes ship assembled, inside a shipper, in runs of 100 to 500 for a kit or a launch. The tray insert die and the foil die are kept, so a second edition is a wrap change.
Booklet Rigid Boxes — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- Grayboard 2 mm covers; 1.5–2 mm tray
- Builds
- Hinged cover over fixed tray; magnetic or ribbon close
- Insert
- Die-cut board, foam or pulp to the product
- Sizing
- A6 to A4 covers; tray 20–60 mm deep; spine from tray depth
- Finish
- Single-sheet wrap; foil on cover and spine; printed inside cover; colored tray liner
- Supply
- Assembled, in a shipper
- Minimum
- 100 boxes
On every job
- Print process
- The wrap is printed offset as a flat sheet and applied to the board, so the print quality is that of a sheet rather than a box.
- Color
- CMYK on the wrap with spot colors for a brand match. A textured or soft-touch wrap mutes a solid color slightly.
- Tolerance
- Board cut plus or minus 0.5 mm. Lid fit is set on a sample and held on the run, with an allowance for the delivery climate.
- Tooling
- No cutting die on the box itself. The tooling is the wrap print and any foil or emboss die, made once and kept.
- Food contact
- A food-grade liner or an inner tray where a rigid box holds unwrapped food.
- Sustainability
- Board and paper recycle together. Magnets, ribbon and foam come out first, and the spec says which the box has.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build booklet rigid boxes on
A rigid box is two materials: the grayboard that holds the shape and the paper wrapped around it. The board decides the feel; the wrap decides everything a customer sees and touches.
Grayboard 1.2–1.5 mm
The light rigid box: jewelry, small cases, card boxes. Heavy in the hand for its size without thick walls on a small cavity.
1.2–1.5 mmGrayboard 2–3 mm
The full rigid box. Resists crushing, bends poorly — thickness is chosen from box size so a wide lid does not sag.
2–3 mmArt paper wrap
Printed coated paper, matte or gloss laminated. Full color, photographs, any design. The most flexible wrap and the least tactile.
128–157gsmSoft-touch wrap
A velvet-feel laminate over printed paper. Reads expensive, shows fingerprints on white, and scuffs at the corners before anywhere else.
128–157gsm laminatedLinen and textured wrap
Texture woven into the paper, so it cannot scuff off. Takes foil and deboss beautifully; breaks up a solid print.
120–140gsmLeather-grain and specialty
Embossed grain papers, metallics and colored stocks. One color and a foil mark, not a photograph.
120–160gsmFlocked and velvet liners
A short-fiber or woven pile for the interior and the insert. Holds a product without marking it and sets the color the piece is seen against.
Applied to board or foamMagnets and hardware
Neodymium magnets under the wrap, ribbon pulls, and hinges built from the wrap itself. Each is a line on the quote.
Per closureNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
On a rigid box the wrap is the finish, and the corners are where it is judged.
Soft-touch wrap
Velvet in the hand. The category default, and it scuffs at the corners first.
Linen and laid
Texture woven into the paper; hides marks and cannot rub off.
Hot foil
Stamped into the wrap. Small block, cheap die, large effect on a lid.
Blind deboss
Shape with no ink. On a textured wrap it is the quietest premium mark there is.
Spot UV on matte
A gloss shape on a matte field; a pattern that only shows at an angle.
Colored liner
A wrap on the inside face, seen for a second as the lid lifts. The cheapest thing that changes an opening.
Leather-grain
Embossed grain paper. One color and a foil mark, never a photograph.
Ribbon and hardware
A pull under the product, magnets under the wrap, a hinge built from the paper.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a rigid box, where the wrap is part of the wall: booklet rigid boxes
A rigid box is built up rather than folded, so the internal size is set first and the board and wrap are added outside it. The lid is then made to fit the base, and that fit is the thing people judge.
- Internal dimensions
- The product plus its insert, at the widest point. Everything else is built outward from this number.
- Wall build-up
- Each wall is the grayboard plus the wrap on both faces — roughly 2.5 mm on a 2 mm board. A small box gains noticeably in outside size.
- Lid clearance
- A few tenths of a millimeter. Set on a plain sample: a slow, air-cushioned lift, not a lid that drops off or has to be prised.
- Insert depth
- The tallest item plus 2 mm. On a two-layer box, this sets the total height and the ribbon lift.
- Humidity
- Board takes up moisture and a lid set snug in a dry factory can bind in a damp shop. We allow for the delivery market.
- Tolerance
- Plus or minus 0.5 mm on a rigid box, tighter than folding board because nothing springs back.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Booklet Rigid Boxes in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about booklet rigid boxes? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
How does a booklet box open?
Like a hardback: the front cover hinges at the spine and lifts to reveal a tray holding the product, then closes on a magnet.
Can the inside of the cover be printed?
Yes, as a page — a message, a routine, instructions — seen as the box opens.
What holds the product?
A die-cut board, foam or pulp insert in the tray, cut to each item.
Will the hinge last?
Yes, when the spine gap is sized to the tray depth and reinforced on deeper boxes. A hinge built too tight is what fails.
Can the spine be foil-stamped?
Yes, and it should be — the spine is what shows on a shelf.
What is the minimum order?
100 boxes.
What sizes are possible?
A6 to A4 covers with trays 20–60 mm deep.
Does it ship flat?
No, book boxes ship assembled inside a shipper.
Magnetic or ribbon closure?
Magnets for a clean, repeatable close; a ribbon tie for a gift look.
Can I change the wrap for a second edition?
Yes. The insert and foil dies are kept; a new edition is a wrap change.
Can I get a sample?
Yes, a plain sample at the finished size with your product in the tray, before print.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
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