Custom Large Cardboard Boxes
Custom large cardboard boxes from 100 — big corrugated boxes for bedding, furniture parts, equipment, moving and bulk orders, sized as tightly as the product allows so dimensional weight does not eat the margin, rated for the load and fitted with hand holes where people lift them.
Big boxes are paid for by their size
- Board
- Corrugated: C flute single wall to BC double wall
- Styles
- RSC, full overlap, telescoping for long items
- Options
- Hand holes, end caps, inserts, reinforced base
Get a price for Large Cardboard 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.
Dimensional weight, briefly
Carriers compare the actual weight with a dimensional weight: length × width × height divided by a set divisor, and charge the higher of the two. For a big, light box, the dimensional weight almost always wins. Cutting an inch from each side of a large box can drop it a price band. Check your carrier’s current divisor when sizing.
Send us the product dimensions and your carrier. We size the box to the product, not to the nearest stock size.
Common large box uses
| Bedding and pillows | Light, compressible; big box, single wall |
|---|---|
| Furniture parts and flat-pack | Long, heavy; double wall and end caps |
| Equipment and appliances | Heavy; double wall with inserts |
| Moving and storage | Standard large sizes with hand holes |
Handling a big box
For carry-out rather than shipping, our cardboard boxes with handles cover the handle options.
- Hand holes on the ends so one person can lift it.
- A double wall or reinforced base for heavy contents.
- Tape the center seam and the edges on heavy loads.
- "Team lift" and weight marks if the box is heavy.
Oversize limits
Parcel networks have maximum sizes and add surcharges above certain lengths and girths. For boxes near those limits, a few inches can move a shipment into freight. We keep the box as small as the product allows and flag any size near a surcharge threshold at quote.
Large Cardboard 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
- Corrugated: C flute single wall to BC double wall
- Styles
- RSC, full overlap, telescoping for long items
- Options
- Hand holes, end caps, inserts, reinforced base
- Plain, 1–2 color flexo, handling marks
- Sizes
- Sized to the product; large moving sizes available
- Delivery
- Flat, bundled
- Minimum
- 100 boxes
On every job
- Print process
- Flexo in one to four colors straight onto the liner; litho-lamination where the box needs full color or a photograph.
- Color
- Flat colors on kraft. Full color needs a white top liner or a laminated sheet, because brown shifts every color warm.
- Tolerance
- Cutting plus or minus 1.5 mm. The flute compresses, so corrugated runs wider than folding board.
- Tooling
- No die on a regular slotted box, which is cut on a slotter. Die-cut mailers and trays need one, made once and kept.
- Food contact
- Food-grade liners and a vented build where the box carries hot food.
- Sustainability
- High recycled content through liners and flute as standard, and the box recycles whole if it is sealed with paper tape.
- 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 large cardboard boxes on
Corrugated is a fluted sheet glued between two liners, and the flute decides nearly everything: how it prints, how it dents, how high it stacks. These are the grades we run.
E flute
About 1.5 mm. Prints well and folds crisply; dents under a stack. Retail boxes, mailers and light shippers.
1.5 mm, single wallB flute
About 3 mm. The working default for parcels — takes print reasonably and stacks reasonably. Most shipping boxes are B.
3 mm, single wallC flute
About 4 mm. More cushioning than B, slightly less stacking strength per weight. Common on grocery and produce cases.
4 mm, single wallBC double wall
B and C glued together, about 7 mm. Heavy or fragile goods, pallet stacking, anything over roughly 15 kg.
7 mm, double wallKraft liner
Brown, strong, absorbent. One or two flat colors flexo print well on it; photographs drink into the brown and go muddy.
Outer and inner linerWhite top liner
A bleached outer liner for full-color print on corrugated. Costs more and marks more easily than kraft.
Outer liner onlyRecycled-content corrugated
High post-consumer fiber through liners and flute. The default for shippers; a slightly grayer brown and no loss of strength at grade.
All flutesCoated and water-resistant
A coating or a wax-free barrier liner for damp stores and cold chains. Check the recycling stream before printing a claim on it.
B and C fluteNot 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.
Corrugated takes fewer finishes than folding board, and the ones it takes it takes well.
Flexo on kraft
One or two flat colors straight onto brown. Cheap, fast, honest.
Litho-lamination
An offset sheet glued to the flute: full color and photographs on a shipper.
Aqueous varnish
Scuff resistance with no film, so the box still recycles whole.
White top print
Full color flexo on a bleached liner; brighter, and it marks more easily.
Inside print
A second pass on the inner liner — the panel a customer sees first.
Printed tape seal
The brand applied at the last moment, on paper tape that recycles with the box.
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 corrugated box against the carrier, not the catalog: large cardboard boxes
Corrugated is cut to your internal size, so the box goes round the product rather than the product going into a stock size. That is where the money is: a box 20 mm smaller each way is often a whole postage band cheaper.
- Internal dimensions
- Length, width and depth of the space you need. Board thickness is added outside that, and the flute is thicker than people expect.
- Clearance and void fill
- 5–10 mm a side for a rigid product. Size it properly and you need no void fill at all, which is cheaper and better received.
- Stacking
- Tell us how high the boxes stack on a pallet or a shelf. Edge crush grade is specified from that, not guessed.
- Weight
- The contents weight sets the flute and the liner grade. Over about 15 kg we move to double wall.
- Score allowance
- Corrugated needs more room at the folds than boxboard. The dieline accounts for it; a box drawn from flat dimensions comes out tight.
- Cutting tolerance
- Plus or minus 1.5 mm on corrugated, wider than folding board because the flute compresses.
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 Large Cardboard 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 large cardboard 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 dimensional weight?
A carrier price based on box volume. Large, light boxes are usually charged on it rather than actual weight.
How do I reduce shipping cost on large boxes?
Size the box closely to the product. An inch less on each side can drop a price band.
Single or double wall for large boxes?
Single wall for light, bulky goods; double wall for heavy contents and furniture.
Can large boxes have hand holes?
Yes, on the ends, placed high to keep the wall strong.
Do you make long boxes?
Yes, often as a telescoping two-piece build for long items.
What about oversize surcharges?
We flag sizes near carrier thresholds at quote so you can decide.
Can you print handling marks?
Yes, weight, team lift and orientation marks.
Are these good for moving?
Yes, standard large moving sizes with hand holes are available.
Can I get end caps for furniture parts?
Yes, die-cut corrugated end caps sized to the part.
How are large boxes delivered?
Flat, with very large sizes strapped in smaller bundles so they can be handled.
What is the minimum order for large boxes?
100 boxes per size. For long telescoping builds, one set counts as one box.
What sets the lead time for large boxes?
Sizes beyond standard sheet widths may need special board. We give a date with the quote.
Same range
More corrugated boxes we make
20x20x20 Cardboard Boxes
100 boxes
Cardboard Boxes
100 boxes
Cardboard Boxes with Handles
100 boxes
Cardboard Boxes with Lid
100 boxes
Corrugated Box Dividers
100 sets
Corrugated Cardboard Inserts
100 inserts
Corrugated Carriers Boxes
100 carriers