Custom Double Wall Cardboard Boxes

More Than Just a Box — It’s Armor for Your Products

From warehouse to doorstep, your packaging should be tough, trusted, and totally on-brand.

Built to Handle What Single-Wall Can’t

We use high-performance corrugated materials engineered for heavy-duty use.

• Twin-flute construction (B+C or B+E flutes) for double the strength
• Supports weights up to 80–120 lbs (depending on size & load)
• Crush-resistant corners and sides
• Moisture-resistant liners available for cold chain or outdoor storage

Custom Sizes & Styles to Fit Your Product Perfectly

We don’t believe in one-size-fits-all packaging — especially for high-value goods.

• Standard RSC (Regular Slotted Carton) or custom die-cut designs
• Available with lids, flaps, interlocking tabs, or handles
• Interior custom inserts, foam, or partitions available
• Pallet-ready sizing or oversize freight formats available

Printing That Makes a Strong First Impression

Your protection can still look polished — and powerful.

• Single-color, multi-color, or full CMYK flexo/offset printing
• Bold logo placement, handling icons, or branded messaging
• Matte, gloss, or eco-kraft finish options
• QR codes, barcodes, or product handling instructions printed directly on box

Add-Ons That Maximize Safety, Storage & Style

Built for impact — both visual and physical.

• Double-ply tape strips for tamper-evidence
• Custom inserts to cradle fragile or tech items
• Perforated tear-off lids or access panels
• Stacking strength ratings (32 ECT, 44 ECT, 51 ECT+ available)

The 3Ps Approach

Presentation

Double wall boxes aren’t just strong — they’re your mobile brand billboard. Make them look sharp and professional in every shipment.

Preservation

Two layers of corrugation protect products from dents, drops, and pressure — keeping contents pristine even in harsh conditions.

Protection

Shock-absorbent, load-tested, and certified to ship industrial products, electronics, glassware, or bulk goods with confidence.

Why 5,000+ Brands Trust Custom Boxes Lab for Tough Shipments

Because we know how to build strength into every fold.

• Low MOQs — ideal for startups or growing logistics
• Custom sizing, layout help & free dieline setup
• Fast U.S. production & nationwide delivery
• Eco-friendly options with recyclable materials
• Packaging specialists who understand freight, storage & fulfillment

Let’s Build Boxes That Mean Business

Whether you’re shipping tech gear, home goods, heavy retail items, or industrial parts — we’ll help you create custom double wall cardboard boxes that go the distance. To get cost-effective packaging boxes without compromising on quality, you can contact us at (469) 649-8706 or email us sales@customboxeslab.com

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.