Custom Corrugated Boxes
Custom corrugated boxes from 100, specified against the journey rather than the shelf. Flute grade, board grade and clearance chosen for how your parcel is actually handled.
Corrugated is a spring, and flute is the spring rate
Get a price for Corrugated 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.
- 8styles 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
8 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.
01See the build →Cardboard Boxes
Custom cardboard boxes cut to your internal size in E, B or BC flute, plain or printed, from 100.
02See the build →Corrugated Box Dividers
Custom corrugated dividers cut to your box and the items it carries, from 100 sets.
03See the build →Full Overlap Containers
Custom full overlap containers built to your internal size in B or BC flute, from 100.
04See the build →Half Slotted Containers
Custom half slotted containers
05See the build →Molded Pulp Boxes
Custom molded pulp boxes and trays formed from recycled fiber to the exact shape of your product, from 500…
06See the build →Regular Slotted Containers
Custom regular slotted containers
07See the build →Retention Boxes
Custom retention boxes that hold a product in a stretched film membrane over a corrugated frame, so it…
08See the build →Small Cardboard Boxes
Custom small cardboard boxes sized to the product, not rounded up to a stock size, from 100.
Side by side
Which corrugated boxes style fits
| Style | Board | Build | Minimum | |
|---|---|---|---|---|
| Cardboard Boxes | Single wall E or B flute; double wall BC; kraft or white top liner | RSC, die-cut mailer, HSC tray, full overlap | 100 boxes | Open → |
| Corrugated Box Dividers | E, B or BC flute; kraft or white liner | Slotted cross partitions, die-cut inserts, layer and bottom pads | 100 sets | Open → |
| Full Overlap Containers | B flute single wall; BC double wall for heavy or pallet-stacked goods | Full overlap (FOL), partial overlap (POL); glued manufacturer's joint | 100 containers | Open → |
| Half Slotted Containers | Single wall 32/44 ECT, double wall 48–71 ECT; C or B flute | FEFCO 0200: bottom flaps only, open top | 100 boxes | Open → |
| Molded Pulp Boxes | Chosen per job | Tray, end cap, cradle insert, clamshell, box with lid | 500 pieces | Open → |
| Regular Slotted Containers | Single wall 32/44 ECT, double wall 48–71 ECT, triple wall; C, B or E flute | FEFCO 0201: four flaps top and bottom, outer flaps meet at the center | 100 boxes | Open → |
| Retention Boxes | PU or PE membrane, 2–4 mil, glued to the frame; low-tack option | Retention (one frame), suspension (two frames), folded-frame retention | 100 packs | Open → |
| Small Cardboard Boxes | E flute or F micro-flute corrugated; 16–20pt folding boxboard for cartons | Self-locking mailer, tuck end carton, tray and sleeve | 100 boxes | Open → |
Flute heights and what they are for
Taller flutes cushion better and print worse — a photograph on C-flute shows the corrugation as visible ridges. If print quality and protection both matter, the answer is usually litho-laminated E-flute rather than a compromise flute.
| F (~0.8 mm) | Retail-quality print, almost no cushioning |
|---|---|
| E (~1.5 mm) | The ecommerce standard — prints well, holds ~2 kg |
| B (~3.0 mm) | Real shock absorption; heavier goods and glass |
| C (~4.0 mm) | Stacking strength; the classic shipping carton |
| BC double-wall (~7 mm) | Export, heavy goods, repeated handling |
Board grade is two numbers, not one
Corrugated is specified as a liner weight plus a flute, and suppliers quote it in different systems — ECT in the US, bursting strength or grammage elsewhere. A "200 grade" box from one supplier is not the same as another's.
What actually matters is the edge crush value for stacking and the bursting strength for puncture. Tell us the weight, the stack height and whether it travels by pallet or parcel, and we will pick the grade rather than asking you to.
Stacking strength drops sharply with humidity — a box rated for a dry warehouse can lose a third of its strength in a damp one.
RSC or die-cut
An RSC is nearly always cheaper per unit than a die-cut mailer of the same internal size, because it wastes less board. The mailer wins where the customer opens it — the trade-offs are in our notes on mailer builds.
- RSC (regular slotted carton). The standard shipping box. Cheapest, needs tape.
- Die-cut mailer. Tapeless, opens cleanly, better unboxing, more board per box.
- Full overlap. Extra base strength for heavy or long journeys.
- Half-slotted with a lid. Reusable, good for returns and rental models.
Print on corrugated, honestly
Flexo prints directly onto the board: cheap, fast, good for one to three colors, and never photographic. Litho lamination prints a sheet separately and glues it to the flute: excellent quality, more expensive, and it wants volume.
Below about a thousand boxes, digital-on-corrugated is increasingly the honest answer — no plates, no lamination, and quality between the two. We will tell you which process your run lands on rather than leaving it in the small print.
Across the range
What every corrugated boxes 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 Corrugated 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 corrugated 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.
What is the minimum order?
100 boxes, printed to your artwork and cut to your dimensions.
Which flute should I choose?
E for light contents and better print, B as the working default, BC double wall for weight and stacking.
Single wall or double wall?
Single wall for most parcels under about 10 kg. Double wall for weight, stacking, or anything sitting under other freight.
Can I print full color on corrugated?
Yes, by litho lamination or digital. Direct flexo is cheaper at volume and limited to simpler artwork.
How much clearance should I leave?
Enough for void fill on all six sides. A tight box transmits impact straight into the product.
Why did my box arrive crushed?
Compression, impact and vibration are three different problems. Board grade answers only the first.
Can the box be a retail box too?
Litho-laminated outers work as both. It costs more than a plain shipper and saves a second box.
Do you supply a dieline?
With every quote, before you commit. It is yours whether or not you order.
Are these recyclable?
Plain corrugated is, in every curbside stream we ship to. Laminates and heavy varnish complicate it.
Can I reorder cheaper?
Yes — the cutting die is kept, so a reorder skips the tooling and goes straight to press.
Which flute for a 5 kg product?
B-flute for parcel shipping, C-flute if it stacks on a pallet. E-flute is not enough at that weight however good the print looks.
Can I get photographic print on corrugated?
On litho-laminated E-flute, yes. Direct flexo on a taller flute will always show the corrugation through the image.
What is ECT and should I care?
Edge crush test — how much stacking load the board takes. Care about it if boxes stack on a pallet; if they ship as single parcels, bursting strength matters more.
Do double-wall boxes need double the board?
Roughly, and they cost accordingly. Only specify double-wall for heavy goods, export or repeated handling — otherwise it is weight you pay freight on.
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