Cardboard Sports Boxes

Packaging That’s Fit for Action

Perfect for sporting goods stores, subscription boxes, fitness brands, and event kits, our cardboard sports boxes are designed to protect, promote, and perform.

Durable Materials That Go the Distance

We use strong, impact-resistant materials that protect your gear and keep your packaging looking sharp—on shelves or in transit.

• Corrugated cardboard (E-flute, B-flute, or double-wall) – Built for bulk, weight, and impact resistance
• Coated or uncoated kraft – Choose from natural or high-gloss finishes
• Optional moisture-resistant coatings – For outdoor gear or weatherproofing
• Recyclable and eco-friendly stock available

Custom Structures That Fit the Gear

From cleats to supplements to branded giveaways, we tailor every box to fit your sports lineup.

• Mailer boxes – Great for eCommerce or subscription-based delivery
• Tuck-top or auto-lock bottom boxes – Ideal for retail or POS displays
• Partitioned interiors – To separate gear, bottles, or accessories
• Reinforced corners and inserts – For high-impact products like balls, weights, or shoes

Bold Printing That Brings the Energy

We turn your cardboard box into a billboard for your brand—bold, athletic, and unforgettable.

• Full-color CMYK or Pantone printing
• Gloss, matte, or soft-touch lamination options
• Foil stamping, embossing, or spot UV – For team logos or signature lines
• QR codes, barcodes, and care instructions built into the design

Features Built for Performance

Our cardboard sports boxes aren’t just tough—they’re practical, efficient, and designed for your workflow.

• Flat-packed for easy shipping and storage
• Quick-assemble construction – No tape or hassle needed
• Die-cut handles or vent holes for carryability and breathability
• Custom inserts for apparel, supplements, or promotional materials

The 3Ps of Cardboard Sports Packaging

Presentation

Bold, athletic packaging that energizes your brand and excites your audience.

Preservation

Sturdy materials and secure construction keep apparel, gear, and accessories safe and dry.

Protection

Shock-absorbing cardboard and custom-fit interiors protect every item in your lineup—no matter the sport.

Why 5000+ Active Brands Choose Us

From fitness startups to pro team merch, we create packaging that fuels sales, builds loyalty, and stands up to shipping stress.

• No minimum order quantity – Great for team kits or limited-edition drops
• Free structural and design consultation
• Fast U.S.-based production and delivery
• Eco-conscious and recyclable board options
• Packaging pros with experience across fitness, sportswear, and gear

Get a Free Quote Today

Put your brand in motion with cardboard sports boxes that deliver strength, style, and standout performance. Call 0000 or email us now to start your custom order with Custom Boxes Lab.

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.