Custom Full Flap Auto Bottom Boxes
Custom full flap auto bottom boxes from 100 — folding cartons whose bottom flaps run the full depth of the box and overlap edge to edge, pre-glued so the base forms on its own and carries a heavier product on a double floor.
A carton floor built from two full layers of board
- Board
- Folding boxboard: 18–24 pt SBS or kraft; E-flute for the heaviest products
- Base
- Full-depth bottom flaps that overlap across the floor, pre-glued auto bottom
- Top
- Straight tuck, tuck with dust-flap lock or hang tab
Order online
Order full flap auto bottom boxes
Starting from $1.20 per unit
Printed to your artwork or plain, sold in runs of 100 up to 5,000 units per product online. Freight to the US, UK, Canada and Australia is inside the price.
How an online order runs
- Add the units you needThen check out with your delivery address. Add other products to the same order on the way.
- A digital proof comes backLaid on the dieline, before anything prints. Change it as often as you need.
- Pay once you approve itPay by PayPal invoice or bank transfer after you approve your digital proof, or cash on delivery in the US and Canada.
- We make it and ship it deliveredYour delivery date is confirmed with the proof, against the spec and your fill date. Freight and customs are handled on the way to you.
Another size, board or finish, or more than 5,000 units? Send the spec for a price instead. Freight by market and our terms cover delivery and remakes.
Get a price for Full Flap Auto Bottom 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.
Where a standard crash-lock runs out of strength
A crash-lock base is quick and neat, but its strength comes from where the flaps hook together. Put a dense product in it, a glass jar, a small appliance, a pack of bath bombs, and the weight sits right on that join. Lift the box from the top and the floor bows; drop it on a corner and the hook can let go.
Full flaps spread the load. Because each flap covers the whole base, the weight bears on a continuous double panel glued along its length, not on a hook. For lighter goods our standard tuck end auto bottom cartons are the cheaper choice and do the job well.
Products that earn the extra board
- Glass jars and bottles of creams, candles and preserves, where a failed base means breakage.
- Electronic devices and chargers sold in a retail carton without an outer shipper.
- Bath bombs and soap packed several to a box, which are heavy for their size.
- Hardware and tools: small parts, fixings and hand tools that concentrate weight in a corner.
- Kits with a booklet and several components, picked up from the top on a store shelf.
Packing line speed stays the same
The base is glued at our end, so the carton arrives flat with the floor already formed. On the packing bench it is squared with one push and the bottom drops into place, exactly as on any auto bottom box. There is no tape and no tucking. The extra board is in the die line, not in anyone’s working time.
Send the product weight with its dimensions. Above a certain weight we will suggest a heavier board or a corrugated build instead.
Picking the board by product weight
| Up to about 1 lb | 18 pt SBS or kraft; the full flaps add plenty of stiffness |
|---|---|
| 1 to 3 lb | 20–24 pt SBS or clay-coated kraft back |
| 3 lb and over | E-flute micro-corrugated with a printed liner |
| Glass or wet product | Add a fitted insert so the item cannot shift onto one edge |
Top closures that pair with a full flap base
The top is chosen separately. A straight tuck flap is the usual pairing and opens toward the front of the shelf. A tuck with a dust-flap lock holds better if the box is carried by its lid, and a hang tab can be added for peg display when the product is light enough to hang. Our wider range of tuck end folding cartons shows the other closures.
Printing a carton that carries weight
All four sides and the top print in full color on the outside, with an optional one-color print inside. The base is rarely seen, so it usually carries the barcode, batch area or recycling mark. Matte or gloss lamination helps the corners survive handling, and foil or spot UV can pick out a logo on the front panel.
Full Flap Auto Bottom 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
- Folding boxboard: 18–24 pt SBS or kraft; E-flute for the heaviest products
- Base
- Full-depth bottom flaps that overlap across the floor, pre-glued auto bottom
- Top
- Straight tuck, tuck with dust-flap lock or hang tab
- Full color outside; optional one color inside
- Finish
- Matte or gloss lamination, foil, spot UV, embossing
- Minimum
- 100 boxes per size
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 full flap auto bottom 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.
280–350gsmMetalized 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: full flap auto bottom 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.
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Build your Full Flap Auto Bottom 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 full flap auto bottom 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 a full flap auto bottom box?
A folding carton whose bottom flaps are cut to the full depth of the box, so they overlap across the whole floor and form a double-layer base that locks on its own.
How is a full flap auto bottom different from a crash-lock bottom?
A crash-lock base holds where its flaps hook together in the middle. A full flap base covers the entire floor with two layers of board, so the weight is not carried by a single join.
How heavy a product can a full flap auto bottom box hold?
In 18–24 pt board it suits products up to about 3 lb. Heavier items move to an E-flute build, and we confirm the board once we know the product weight.
Do full flap auto bottom boxes need tape?
No. The base is glued during manufacture, so the box opens square and the floor drops into place without tape.
Are full flap auto bottom boxes good for glass jars?
Yes. The double floor stops a jar pressing through the base, and a fitted insert keeps it from shifting onto one edge.
What do you need to quote a full flap auto bottom box?
The product dimensions and weight, the quantity and the top closure you want. A dieline comes with the quote so you can check the fit.
Can a full flap auto bottom box have a hang tab?
Yes, for products light enough to hang on a peg. The tab is part of the top flap and is die-cut with the box.
Which top closure goes with a full flap auto bottom box?
Usually a straight tuck flap. A dust-flap lock is better if the box is carried by its lid, and reverse tuck is possible for a front-opening display.
Can the inside of a full flap auto bottom box be printed?
Yes, in one color. Most buyers print a message on the inside of the lid and leave the base plain.
Is a full flap auto bottom box more expensive than a standard one?
Slightly, because the bottom flaps use more board. For heavy or fragile products the stronger floor usually saves more than it costs.
Can I get a full flap auto bottom box in kraft?
Yes. Kraft board prints well in darker colors and gives the carton a natural, uncoated look while keeping the same base.
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