Custom Cardboard Sheets
No folds, no print, no shape — a sheet of board cut to a dimension. It is the least interesting thing on this site and it quietly solves a surprising number of the problems the rest of it is designed around.
Get a price for Cardboard Sheets
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- 2styles in this range, each with its own page and price
- 100unit minimum on every style, printed or plain
- 4markets quoted in the delivery currency
- ±1mmcutting tolerance on folding board, checked on a sample
2 styles in this range
Styles we make in this range
Every one below is written up, priced and dielined. Tap a style to see how it is built.
Side by side
Which cardboard sheets style fits
| Style | Board | Build | Minimum | |
|---|---|---|---|---|
| Cardboard | Grayboard 1–3 mm; corrugated E/B/BC; boxboard 14–24pt; WLC; kraft 300–600 gsm | Guillotined sheets; die-cut blanks with shapes, slots or windows | 100 sheets | Open → |
| Round Cardboard | Grayboard 1.5–3 mm, E/B flute, white lined chipboard, kraft board | Plain discs, food-grade cake circles, lid inserts, layer pads | 100 discs | Open → |
What flat board is actually used for
The separator use is the one most often skipped and most often needed. A thin sheet between two fragile items costs almost nothing and removes the single commonest cause of breakage.
| Layer pads | Between rows on a pallet, so the layer above does not crush the one below |
|---|---|
| Box liners | A flat sheet in the base of a box, spreading load and protecting the base |
| Stiffeners | In a flat mailer, so prints and documents cannot bend |
| Cake and pizza discs | Round board under a product, so it can be lifted intact |
| Separators | Between glass or ceramic items, so nothing touches anything |
Grades, and choosing more sensibly than by thickness
For layer pads and separators, stiffness across the sheet is what matters, and single wall B flute usually beats a thicker solid board because the flutes resist bending.
For stiffeners in flat mailers the opposite is true — a solid grayboard or a heavy pulpboard stays flatter and does not show a flute pattern through a print. The board behavior is set out in our flute and board grade notes.
Corrugated flutes emboss their own pattern into anything soft pressed against them. Never put bare corrugated directly against a print or a photograph.
Round board is a different cut
- Discs are cut with a rotary die rather than a straight knife, which is a separate tool.
- Cake and pizza boards are often food-grade one side and plain the other.
- A greaseproof or laminated face is what stops a board going soft under a cake.
- Standard diameters are cheaper than bespoke ones, because the tool already exists.
Sizing to what it goes into
A layer pad should be a few millimeters under the internal dimensions of the case, not equal to them. A pad cut to the exact internal size buckles when it is dropped in, and a buckled pad does not spread load.
A stiffener is the opposite — it should be larger than the item it protects, so an impact at the corner hits the board rather than the print.
Where it replaces something more expensive
A great many problems that get solved with foam, molded pulp or a bigger box are solved by a flat sheet in the right place: a separator between two items, a liner under a heavy product, a stiffener behind a print.
It is worth trying the cheap answer first. A sheet of board costs pennies and it is the quickest thing to test before committing to tooling.
Across the range
What every cardboard sheets job runs on
Boards
- Natural kraft
- White SBS
- E and B flute
- Wrapped grayboard
- Food-grade board
- Recycled content
Chosen from what goes in the box and how far it travels. Our notes on recyclable and compostable stocks say which claims each board can carry.
Finishes
- Matte
- Gloss
- Soft-touch
- Foil
- Emboss
- Spot UV
- Kraft
- Textured
Each one is a decision about light on a shelf — the specialty finishes range shows them on real boxes.
Artwork
- Vector PDF or AI, fonts outlined
- 3 mm bleed, 4 mm safe area
- CMYK; a spot color where a match must hold
- Proof on the dieline before press
Files not set up that way are fine — see the guide to preparing print files.
Interactive · five steps · no sign-up
Build your Cardboard Sheets 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 cardboard sheets? 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.
What board for a pallet layer pad?
Single wall B flute usually beats a thicker solid board — the flutes resist bending across the sheet.
Can I put corrugated straight against a print?
No. The flutes emboss their pattern into anything soft under pressure. Use solid board or an interleaf.
Should a layer pad be the exact internal size?
A few millimeters under. Cut exact, it buckles going in, and a buckled pad spreads no load.
Are round boards more expensive?
In standard diameters, no — the rotary tool already exists. Bespoke diameters carry a tooling charge.
What is the minimum order?
100 sheets or discs.
Are cake boards food-safe?
Food-grade and greaseproof-faced on one side as standard, so a cake can be lifted intact without the board going soft.
What board for a pallet layer pad?
Single wall B flute usually beats a thicker solid board — the flutes resist bending across the sheet, which is what a pad has to do.
Can I put corrugated straight against a print?
No. The flutes emboss their pattern into anything soft under pressure. Use solid board or an interleaf.
Should a layer pad be the exact internal size?
A few millimeters under. Cut exact, it buckles going in, and a buckled pad spreads no load.
Are round boards more expensive?
In standard diameters, no — the rotary tool already exists. Bespoke diameters carry a tooling charge.
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