Custom Charger Boxes
Custom charger boxes for adapters, wireless pads, power banks and cables — a small carton with an insert that holds the unit and coils the cable, a window if you want it — from 100. Dieline and price the same working day.
Small, dense, and sold next to forty others like it
- Board
- 18–20pt boxboard, laminated; rigid tray for power banks
- Builds
- Tuck carton with insert, window carton, sleeve and tray, lidded box
- Insert
- Die-cut board platform or molded pulp; cable cut-out
Get a price for Charger 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.
Carton formats by product
| Wall adapter | Tuck carton with a board insert holding the plug pins clear; window optional; hang tab |
|---|---|
| Wireless charging pad | Flat carton with a platform; window over the pad |
| Power bank | Sleeve over a tray, or a lidded box; the weight wants a rigid tray |
| Cable | Small carton with a coiled-cable insert or a window sleeve around a coil |
The insert that holds the block and the cable
A charger rattling in a box is what a customer notices first. A die-cut board platform holds the body in a cut-out with the pins in a slot, and a second cut-out takes the cable coiled and tied. Molded pulp does the same in one piece for a larger unit. The insert is drawn from the product; a photograph beside a ruler is enough for a small adapter.
The front panel: three facts
Everything else goes on the sides and back. A shopper compares chargers on wattage and ports; the box that shows them first is the one picked up.
- Wattage, in the largest type on the box.
- Plug type and the ports — USB-C, USB-A, how many.
- What it charges — a phone, a laptop, both — as an icon row.
The regulatory back
Chargers carry more marks than almost any small product — safety marks per market, input and output figures, warnings, a barcode, recycling symbols. On a box 70 mm wide that is a design problem, solved by reserving the whole back panel and one end for it at the dieline stage. Our electronics boxes for accessories and devices cover the wider range of small-device cartons.
Tell us every market the charger sells in. The marks differ, and the panel is sized to the longest list.
Board, finish and the peg
18–20pt boxboard, matte or gloss laminated, with a hang tab or Euro-slot for a peg and a flat base for a shelf. A window shows the charger and its color; a printed image on the front does the same for less and keeps the box mono-material. Cartons ship flat and load from the end.
Charger 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
- 18–20pt boxboard, laminated; rigid tray for power banks
- Builds
- Tuck carton with insert, window carton, sleeve and tray, lidded box
- Insert
- Die-cut board platform or molded pulp; cable cut-out
- Panels
- Wattage and ports on front; full regulatory back and end
- Options
- Window, hang tab or Euro-slot, tamper seal
- Full color, laminated; icon row
- Minimum
- 100 boxes
On every job
- Print process
- Digital below about a thousand, offset above it. One side or both, with spot colors where a match has to hold.
- Color
- CMYK as standard. Uncoated and kraft stocks print lighter and warmer; a spot color is the only exact match.
- Tolerance
- Cutting plus or minus 1 mm, creasing plus or minus 0.5 mm, confirmed on a plain sample before the run.
- Tooling
- A cutting die per size, made once and kept. Foil and emboss dies per artwork, also kept.
- Food contact
- Food-grade board and inks where the carton touches food, with the interior left plain.
- Sustainability
- Mono-material board wherever the product allows; recycled-content and FSC stocks; no claim printed the pack does not earn.
- 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 charger boxes on
A folding carton is one sheet of board, so the board is the product. These are the stocks we run for cartons, what each is good at, and where it lets you down.
Natural kraft
Unbleached folding board. Warm, hides marks, costs least. Mutes color — one or two flat colors print well, photographs do not.
250–350gsm sleeves; 14–24pt cartonsWhite SBS
Solid bleached sulfate: bright, coated, the retail carton standard. Takes accurate color and every finish. Shows scuffs sooner than kraft.
14–24ptWhite lined chipboard
A recycled gray core under a white printing face. Cheaper than SBS and slightly duller; the back of the sheet stays gray.
16–24ptKraft-look coated
A kraft face over a coated inner. The natural look with a barrier behind it — the answer where oil, grease or moisture would mark plain kraft.
14–20ptRecycled-content board
Post-consumer fiber with a gray-brown cast. Right for outers and inner components; poor for bright whites and photography.
16–22ptMicro-flute E and F
A fine corrugated layer where a carton needs structure it cannot get from board — a large panel, a heavy product, a box that ships alone.
E 1.5 mm; F 0.8 mmUncoated and textured
No clay coat, or a linen or laid grain. Print reads softer and warmer; a deboss goes deeper. Photographs do not sit well on it.
280–350gsmMetallised and pearlescent
A metallic or pearl face for a shelf that needs to catch light. Costly, and it fights a photograph — a mark or a pattern suits it better.
16–20ptNot 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.
Every finish here is a decision about light on a shelf, not about luxury.
Matte lamination
Reads considered, hides marks, takes a ballpoint.
Gloss lamination
Lifts color; glares under shop lighting.
Soft-touch
Velvet in the hand; shows fingerprints in a bag.
Hot foil
Real metal leaf — the most reliable premium signal.
Emboss / deboss
Shape with no ink; works in the dark.
Spot UV
Gloss shapes on a matte field.
Uncoated kraft
Warm, natural, mutes color.
Textured stock
Texture in the paper; cannot scuff off.
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 folding carton so the die comes out right: charger boxes
Measure the product, not the box it is in now. A carton is built around what has to fit inside it, assembled — cap on, lid fitted, folded if it folds — at its widest point in each direction. Send those three numbers and say which is which.
- Length x width x height
- Internal, always. External dimensions include the board and are what the carrier measures, not what the product needs.
- Clearance
- 2–3 mm a side for a snug fit; more where an insert or void fill goes in. A carton cut exactly to the product is slow to pack and transmits every knock.
- Board thickness
- Heavier board takes internal space from the product. It matters most on small boxes, where four walls of 24pt is a real share of the cavity.
- Varies between batches?
- Glass, textiles, molded parts and cured soap all do. Measure several and build to the largest.
- Cutting tolerance
- Plus or minus 1 mm on folding board. Confirmed on a plain sample before the run.
- Units
- Metric or imperial, as long as you say which. Mixing them in one spec is where mistakes happen.
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 Charger 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 charger 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.
Can the box hold the charger and the cable together?
Yes, with a board insert that has a cut-out for the body and a second for the coiled cable.
Can I have a window?
Yes, over the charger. A printed image on the front does the same job for less and keeps the box all paper.
Where do the regulatory marks go?
On the back panel and one end, reserved on the dieline. Tell us the markets so the panel is sized to the longest list.
Can it hang on a peg?
Yes, with a hang tab or a Euro-slot, and a flat base for the shelf.
What board do you use?
18–20pt boxboard, laminated. Power banks get a rigid tray for the weight.
What is the minimum order?
100 boxes.
Does it ship flat?
Yes, cartons and inserts. They pop open and load from the end.
Can one box serve several wattages?
Yes, with a reserved panel for a label, or a print change on the same die.
Can the box be tamper sealed?
Yes, with a seal sticker or a perforated tuck.
Do you make boxes for cables alone?
Yes, a small carton with a coil insert or a window sleeve around the coiled cable.
Do you keep the die?
Yes, so a new model on the same size is a print change only.
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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