Custom Full Overlap Container

Designed for Heavy-Duty Needs

Full overlap containers are perfect for shipments that demand structural integrity. Whether you’re packaging industrial tools, glassware, or e-commerce goods, these containers prevent crushing, tearing, and corner damage during transit or stacking.

Materials

Select the most suitable board grade to match your product’s weight and handling needs:

• Double-wall corrugated – for bulk or fragile contents
• Triple-wall corrugated – for ultra-heavy-duty protection
• Kraft – for eco-friendly appeal
• White corrugated – for crisp, professional prints

Sizes

Customize to the exact dimensions of your product to eliminate empty space and reduce movement:

• Compact sizes for electronics or cosmetics
• Standard dimensions for shelf-ready boxes
• Oversized formats for machinery or multiple units
• Custom depths and widths for snug fit

Prints

Ensure your packaging stands out with high-quality, brand-consistent printing:

• CMYK and PMS printing for precise color accuracy
• Logo placements and instructional prints
• Large print areas for product visuals
• Exterior and interior printing options available

Add-ons

Enhance the structure and appearance of your custom box with practical and decorative additions:

• Reinforced handles for carrying
• Cushioning inserts and foam lining
• Tamper-evident closures
• Custom labels or QR code tags

Types of Boxes

We offer full overlap containers tailored to various industries and product categories:

• Custom shipping boxes for tools and parts
• Reinforced packaging for electronics
• Heavy-duty mailers for e-commerce
• High-volume transport boxes for industrial supply chains

3Ps Approach

Our custom containers are built to deliver on the three core packaging values: Presentation, Preservation, and Protection.

Presentation

Even industrial-grade boxes can be branded with professional visuals, making your shipments look intentional and organized.

Preservation

By eliminating open seams and minimizing exposure, full overlap flaps preserve product condition against dust, moisture, and pressure.

Protection

The overlapping panels double the resistance against impacts, making these boxes excellent for demanding transportation routes.

Upgrade to Premium Packaging

Add a refined touch to your rugged container with premium finishes:

• Matte or gloss lamination
• Embossing and debossing for logos
• Spot UV for callouts and safety warnings
• Color-matched fluting edges

Why Choose Us?

We offer custom full overlap containers that are practical, durable, and professionally customized. Our team works closely with you to ensure your box meets industry standards, transit expectations, and branding requirements. Here’s what you get:

• Free box structure consultation
• Strong, recyclable materials
• High-speed production and bulk discounts
• Low MOQ and responsive service
• Nationwide delivery at no added cost

Get A Quote

Need boxes that can handle pressure and promote your brand? 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.