Custom Gym and Fitness Boxes
Custom gym and fitness boxes — supplement cartons, band and glove boxes, apparel mailers, subscription kits with a divider — printed in a look that belongs in a gym, from 100. Dieline and price the same working day.
Packaging for products that are sold on results and bought on the box
- Board
- 18–24pt food-grade boxboard; E flute white-lined mailers
- Builds
- Tuck carton, dispenser carton, multipack, window carton with insert, mailer, divided kit
- Inserts
- Slotted board for bands, wells for grips, platform for gloves, kit divider
Get a price for Gym & Fitness 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.
Products and their boxes
| Supplements: tubs, sachets, bars | Tuck carton around a tub; sachet dispenser box; bar multipack |
|---|---|
| Resistance bands, straps, grips | Window carton with a board insert; hang tab |
| Gloves, wraps, belts | Window carton or a lidded box; sized to the pair |
| Apparel | A mailer with inside print; sized to the fold |
| Subscription kit | A divided mailer holding a mix of the above |
The look, honestly
Our sports packaging across every sport covers the equipment boxes for balls, bats and boots.
- Black or a dark ground with one strong accent — the category convention, for a reason.
- The claim in the largest type: the grams, the resistance, the count.
- A photograph or an icon of the product in use, not a lifestyle shot.
- Regulatory panels — supplement facts, warnings — reserved on the back at the dieline stage.
Supplement cartons and the tub inside
A carton around a tub is a tuck box sized to the tub plus 2 mm, with a crash-lock base for the weight and a window if the tub label is the design. Sachets go in a dispenser carton with a tear-open front; bars in a multipack with a perforated display top. All on 18–24pt food-grade boxboard with the supplement facts panel reserved.
Gear boxes and the insert
Bands and grips tangle and rattle. A board insert with a slot per band or a well for a grip holds them in a window carton so the product reads through the window and does not move. Gloves sit on a platform in pairs. The insert is drawn from the product and cut on the same die as the carton.
Rubber and silicone products react with some board coatings over months on a shelf. We use a plain interior and specify accordingly.
Subscription and starter kits
A fitness subscription box is a divided mailer: a tub or sachets, a band, a shaker, a card with the month's program. The divider is sized to a few standard cells so the contents change without the box changing, and the card is printed digitally each month. Inside-lid print carries the brand message.
Gym & Fitness 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
- 18–24pt food-grade boxboard; E flute white-lined mailers
- Builds
- Tuck carton, dispenser carton, multipack, window carton with insert, mailer, divided kit
- Inserts
- Slotted board for bands, wells for grips, platform for gloves, kit divider
- Full color; dark grounds with accent; supplement facts and warnings reserved
- Interior
- Plain, for rubber and silicone products
- Kit
- Standard cells; monthly digital card
- 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 gym & fitness 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: gym & fitness 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 Gym & Fitness 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 gym & fitness 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 one supplier make all my fitness packaging?
Yes: supplement cartons, gear boxes, apparel mailers and subscription kits, on one print system so the range matches.
Do you reserve space for supplement facts?
Yes, on the back at the dieline stage, and the proof is checked against your approved panel.
How do you stop bands tangling in the box?
A slotted board insert holds each band in the window carton, cut on the same die.
Can the box hang on a peg?
Yes, gear cartons take a hang tab or a Euro-slot.
What is the minimum order?
100 boxes.
Is the board food safe for supplements?
Yes, food-grade boxboard for anything holding sachets or bars directly.
Can the subscription box change monthly without a new box?
Yes — a divider with standard cells and a card printed digitally each month.
Will rubber products mark the box?
Not with a plain interior, which we specify for rubber and silicone.
Can I print a dark box?
Yes, full black or dark grounds with an accent print, laminated matte.
Does it ship flat?
Yes, all formats, with inserts flat.
Can I have a window on the supplement carton?
Yes, over the tub label, if the label is the design.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
Same range
