Custom Printed Medical Device Packaging

More Than Just a Box — It’s Peace of Mind in Every Panel

We design for sterile environments, user clarity, and durable transport — all backed by compliant printing and structural precision.

Medical-Grade Materials Built for Protection

Form meets function with materials engineered to handle your most sensitive items.

• FDA-compliant, medical-grade SBS, kraft, or barrier-coated stock
• Moisture, UV, and puncture-resistant layers for cleanroom or transport safety
• Tamper-evident and sterilization-compatible formats available
• Ideal for surgical kits, diagnostic devices, cartridges, test kits, and wearable tech

Custom Printing That Communicates with Confidence

We print clear, precise, and brand-aligned packaging that supports clinical and retail distribution.

• CMYK or Pantone printing for logos, directions, or international compliance marks
• Multilingual copy, dosage icons, barcodes, and UDI (Unique Device Identifier) printing
• Optional variable data for lot numbers, batch codes, expiration dates
• Inside-and-outside printing for instructions, visual assembly guides, or branding

Sized and Structured to Fit Every Device and Use Case

From shelf-size to surgical trays — we box to match your delivery, storage, and display needs.

• Flat-packed cartons, two-piece boxes, or slide trays
• Built-in die-cut inserts for vials, tubes, sensors, or sterile packs
• Tear-off lids, tab closures, or child-resistant formats
• Custom inserts made from foam, pulp, or recyclable board for safe device handling

Add-On Features That Align with Compliance and Brand Goals

Because function, safety, and design should work hand-in-hand.

• Tamper-evident seals, heat-sealed flaps, or breakable labels
• QR codes for digital IFUs (Instructions for Use), setup videos, or registration
• Sterilization indicator printing or labels for EO/gamma/radiation processes
• FSC®-certified and recyclable options to meet sustainability requirements

The 3Ps Approach

 Precision

Exact structural fits and regulatory-compliant layouts ensure every device is safely and accurately presented.

 Protection

Your packaging serves as the first layer of defense — against contamination, impact, or tampering.

 Presentation

From hospital to retail shelf, your box represents the professionalism, trust, and innovation behind your product.

Why Healthcare Startups, OEMs, and Pharmas Trust Custom Boxes Lab

• Free dieline setup and layout review for compliance
• Production-grade prototypes and drop testing available
• Variable printing for batch control and serialization
• Fast U.S. manufacturing with short lead times and fulfillment support
• Trusted by medtech innovators, surgical kit makers, and diagnostics companies

Let’s Build Medical Device Packaging That Protects and Performs

From pre-launch pilots to full-scale production runs, we help you create custom printed medical device packaging that’s safe, smart, and strong enough to carry your reputation. Call us at 0000 or email today to get started with Custom Boxes Lab.

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Need outer cartons, clamshell trays, or sterile barrier pouches? Let’s design your complete medical packaging system — with structure, clarity, and brand confidence built in.

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.