Custom Rigid Hexagon Boxes
Custom rigid hexagon boxes — six wrapped sides, a lid that lifts off or hinges — from 100 units. A shape that stands out on a shelf without a single word of print, built so the six corners meet cleanly and the lid drops on straight every time.
Six sides, six corners, and a lid that has to land on all of them
- Board
- 1200–1800 gsm chipboard, six wrapped walls, hexagon base and lid discs
- Shapes
- Regular, elongated, hexagon tube; 3–10 in across the flats
- Lid
- Lift-off cap, hinged with printed inside, magnetic catch
Get a price for Rigid Hexagon 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.
How six panels become a box
A rigid hexagon is built from a single scored board blank folded into six walls, or from six separate panels taped at the corners, then a base disc and a lid built the same way. The wrap paper goes on afterward and has to turn six corners without creasing or showing a seam on a visible face — we put the wrap seam at the back corner and fold the paper in mitered turns so it lies flat. The base and lid are cut as hexagons on a die, which means one die per size, not one per box.
| Regular hexagon | Six equal sides, the classic; 3–10 in across the flats |
|---|---|
| Elongated hexagon | Two long sides, four short; suits a bottle or a wide product |
| Hexagon tube | Tall six-sided box with a cap; for candles, bottles, rolled goods |
The lid, and landing it straight
A lift-off hexagon lid has to be cut to the outer dimension of the base plus a paper thickness, on all six faces, and any error shows as a lid that sits proud on one side. We build the lid and base from the same board batch and check the fit on a jig. A hinged version — the lid attached along one flat — solves the landing problem and gives a printed inside lid, and it is built on the same hinge as our hinged lid boxes that open like a book. A magnetic catch on the flat opposite the hinge is the premium version.
A shallow lid — a cap of an inch or so — is easier to seat than a deep one and shows more of the base wrap. Most hexagon boxes are better with a cap than a half-depth lid.
Inserts for a shape with no square corners
- A hexagonal platform with a circular cut-out — a candle, a jar, a round tin.
- A foam or flocked tray cut to the six sides, with a cavity for a watch or a bracelet.
- A ring or a small jewelry cushion in the center, with the six walls as the frame.
- A circular product in a hexagon reads as intentional; a rectangular one does not, and needs a platform to sit square inside the shape.
Where the shape earns its cost
A hexagon costs more than a square box of the same volume — more corners, more wrapping time, its own dies — and it is worth it where the box is the display: candles, fragrance, artisan food, and jewelry sold in the box. It is not worth it for a product that is unboxed and the box discarded. The shape also nests badly for freight; hexagons ship assembled and leave gaps in the carton. For a round product where the shape matters but nesting does too, the wound tube on our round gift boxes built as a wrapped tube page ships tighter.
Rigid Hexagon 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
- 1200–1800 gsm chipboard, six wrapped walls, hexagon base and lid discs
- Shapes
- Regular, elongated, hexagon tube; 3–10 in across the flats
- Lid
- Lift-off cap, hinged with printed inside, magnetic catch
- Wrap
- 120–157 gsm paper, mitered corners, seam at the back
- Inserts
- Hexagonal platform, foam or flocked tray, jewelry cushion
- Finishes
- Foil, emboss, soft-touch, spot UV
- Minimum
- 100 boxes
On every job
- Print process
- The wrap is printed offset as a flat sheet and applied to the board, so the print quality is that of a sheet rather than a box.
- Color
- CMYK on the wrap with spot colors for a brand match. A textured or soft-touch wrap mutes a solid color slightly.
- Tolerance
- Board cut plus or minus 0.5 mm. Lid fit is set on a sample and held on the run, with an allowance for the delivery climate.
- Tooling
- No cutting die on the box itself. The tooling is the wrap print and any foil or emboss die, made once and kept.
- Food contact
- A food-grade liner or an inner tray where a rigid box holds unwrapped food.
- Sustainability
- Board and paper recycle together. Magnets, ribbon and foam come out first, and the spec says which the box has.
- 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 rigid hexagon boxes on
A rigid box is two materials: the grayboard that holds the shape and the paper wrapped around it. The board decides the feel; the wrap decides everything a customer sees and touches.
Grayboard 1.2–1.5 mm
The light rigid box: jewelry, small cases, card boxes. Heavy in the hand for its size without thick walls on a small cavity.
1.2–1.5 mmGrayboard 2–3 mm
The full rigid box. Resists crushing, bends poorly — thickness is chosen from box size so a wide lid does not sag.
2–3 mmArt paper wrap
Printed coated paper, matte or gloss laminated. Full color, photographs, any design. The most flexible wrap and the least tactile.
128–157gsmSoft-touch wrap
A velvet-feel laminate over printed paper. Reads expensive, shows fingerprints on white, and scuffs at the corners before anywhere else.
128–157gsm laminatedLinen and textured wrap
Texture woven into the paper, so it cannot scuff off. Takes foil and deboss beautifully; breaks up a solid print.
120–140gsmLeather-grain and specialty
Embossed grain papers, metallics and colored stocks. One color and a foil mark, not a photograph.
120–160gsmFlocked and velvet liners
A short-fiber or woven pile for the interior and the insert. Holds a product without marking it and sets the color the piece is seen against.
Applied to board or foamMagnets and hardware
Neodymium magnets under the wrap, ribbon pulls, and hinges built from the wrap itself. Each is a line on the quote.
Per closureNot 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.
On a rigid box the wrap is the finish, and the corners are where it is judged.
Soft-touch wrap
Velvet in the hand. The category default, and it scuffs at the corners first.
Linen and laid
Texture woven into the paper; hides marks and cannot rub off.
Hot foil
Stamped into the wrap. Small block, cheap die, large effect on a lid.
Blind deboss
Shape with no ink. On a textured wrap it is the quietest premium mark there is.
Spot UV on matte
A gloss shape on a matte field; a pattern that only shows at an angle.
Colored liner
A wrap on the inside face, seen for a second as the lid lifts. The cheapest thing that changes an opening.
Leather-grain
Embossed grain paper. One color and a foil mark, never a photograph.
Ribbon and hardware
A pull under the product, magnets under the wrap, a hinge built from the paper.
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 rigid box, where the wrap is part of the wall: rigid hexagon boxes
A rigid box is built up rather than folded, so the internal size is set first and the board and wrap are added outside it. The lid is then made to fit the base, and that fit is the thing people judge.
- Internal dimensions
- The product plus its insert, at the widest point. Everything else is built outward from this number.
- Wall build-up
- Each wall is the grayboard plus the wrap on both faces — roughly 2.5 mm on a 2 mm board. A small box gains noticeably in outside size.
- Lid clearance
- A few tenths of a millimeter. Set on a plain sample: a slow, air-cushioned lift, not a lid that drops off or has to be prised.
- Insert depth
- The tallest item plus 2 mm. On a two-layer box, this sets the total height and the ribbon lift.
- Humidity
- Board takes up moisture and a lid set snug in a dry factory can bind in a damp shop. We allow for the delivery market.
- Tolerance
- Plus or minus 0.5 mm on a rigid box, tighter than folding board because nothing springs back.
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 Rigid Hexagon 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 rigid hexagon 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.
Does the lid sit straight?
Yes — the lid and base are cut from the same board batch and checked on a jig, so the lid lands on all six faces. A hinged lid avoids the question entirely.
Can the lid be hinged?
Yes, along one flat, with a printed inside and an optional magnetic catch on the opposite flat.
Are the corners clean?
Yes. The wrap is turned in mitered folds at each corner and the seam is placed at the back, so no visible face shows a join.
What goes in a hexagon box?
Candles, jars, fragrance, artisan food and jewelry — round or small products that sit centered in the shape. A rectangular product needs a platform.
Can it be tall?
Yes, as a hexagon tube with a cap, for candles, bottles and rolled goods. It is built the same way with taller walls.
How big can it be?
Up to about 10 in across the flats as a regular hexagon. Larger is possible in a heavier board, but the lid gets hard to seat.
Does it ship flat?
No — rigid hexagons ship assembled. They nest poorly, so freight per box is higher than a square box of the same size.
Can I have an insert?
Yes, a hexagonal platform with a cut-out, a foam or flocked tray, or a jewelry cushion. Send us the product and we cut to it.
Is it more expensive than a square box?
Yes — more corners, more wrapping time, and its own dies. It pays where the box is the display and not where the box is discarded.
What is the minimum order?
100 boxes. Each size has its own hexagon die; the set-up is in the dies and the wrapping.
How long does production take?
Longer than a square rigid box — six corners to wrap by hand. We give a date with the quote.
Will you send a sample?
A white sample in your size, so you can check the lid seat and the fit of your product before print.
Same range
