Custom Gym Fitness Box

Designed for Performance and Branding

Fitness packaging must be tough, well-structured, and bold. We build boxes that keep products secure during transit while showcasing the lifestyle your brand promotes.

Materials

Durability and design go hand in hand with our fitness box material options:

• Corrugated – Strong and perfect for heavy or multiple items
• Rigid Board – High-end presentation for luxury fitness gear
• Kraft – Eco-friendly and sturdy for minimalist brands
• SBS Paperboard – Ideal for bold, detailed printing

Sizes & Fit

No matter your product mix, we size the box to fit:

• Protein tubs, shaker bottles, or resistance bands
• Apparel kits and gym gear bundles
• Foam inserts or dividers to separate items securely
• Flat-pack or assembled styles depending on your needs

Printing Options

Bring your fitness brand to life with dynamic printing:

• High-energy designs and logos
• Full-color or spot UV for bold impact
• Motivational taglines and branded messaging
• Interior printing for an enhanced unboxing moment

Add-ons & Features

Upgrade function and appearance with powerful add-ons:

• Magnetic closures or tuck-end openings
• Die-cut windows to preview product
• Custom inserts for secure product placement
• Printed QR codes linking to workouts or promo content

Types of Fitness Boxes

We create versatile solutions for gyms, trainers, and fitness brands:

• Fitness subscription packaging
• Merchandise and apparel boxes
• Supplement kits and promo boxes
• Retail display packaging for active lifestyle products

3Ps of Fitness Packaging

Presentation

Well-designed boxes help sell the lifestyle before the product is even touched—perfect for shelf presence and social media.

Preservation

Keep supplements fresh, gear safe, and apparel folded neatly with strong, form-fitting packaging.

Protection

Our boxes handle shipping and handling with ease, ensuring no damage during delivery or unboxing.

Upgrade to Premium Fitness Boxes

Level up your packaging for maximum brand value:

• Foil-printed logos or embossed branding
• Water-resistant matte coatings
• Spot gloss over bold typography
• Textured surfaces for a rugged feel

Why Choose Custom Boxes Lab?

From startups to elite fitness brands, we craft boxes that perform as hard as your products do.

• Free expert design assistance
• Eco-friendly packaging options
• Bulk discounts and fast turnaround
• No minimum order quantity

Get a Quote Today

Ready to flex your brand with powerful packaging? Call us at 0000 or email us to create your custom gym fitness boxes 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.