Double Wall Corrugated Boxes

Packaging That’s Strong, Secure & Supply-Chain Ready

Perfect for shipping, warehousing, exports, and high-weight products—our double wall boxes are trusted by thousands of brands for their unmatched durability.

Built with Two Layers of Strength

We use premium corrugated board with two flutes—designed to resist compression, punctures, and moisture.

• B-flute + C-flute combination – The industry standard for extra stacking and crushing resistance
• E-flute + B-flute option – Strong yet compact for tighter packaging needs
• Brown kraft or white outer liners – Clean look, great printability, and eco-appeal
• Coated or uncoated finishes – Choose matte, gloss, or plain industrial textures

Custom Sizes & Styles to Fit Your Workflow

We tailor every box to your load size, handling requirements, and product fragility.

• Shipping boxes (RSC, FOL, HSC) with flaps for sealing
• Die-cut styles for custom shapes and inserts
• Pallet-ready boxes for export packaging
• Flat-pack designs for efficient storage and delivery

Print & Branding Options for a Professional Edge

Even tough boxes can look polished. Elevate your shipping with branded presentation.

• One-color logos or full CMYK printing
• Custom barcodes, handling icons, or QR codes
• Internal printing for unboxing experiences
• Stamping or labeling areas for warehouse and SKU tracking

Built-in Protection for Your Heaviest Products

Double wall boxes are ideal for:

• Electronics, machinery parts, or automotive tools
• Bulk orders, wholesale packaging, and B2B shipments
• Fragile products that need extra impact absorption
• Long-distance or overseas transportation

The 3Ps of Double Wall Corrugated Box Packaging

• Presentation: Strong doesn’t mean plain—our boxes can be branded, printed, and customized for a clean shipping experience.
• Preservation: Dual-wall structure protects contents from crushing, humidity, and transport damage.
• Protection: Ideal for stacking, long hauls, and storage—engineered to hold weight and withstand impact.

Why 5000+ Businesses Trust Our Corrugated Packaging

From manufacturers to distributors and eCommerce brands, we supply corrugated packaging that works as hard as you do.

• No minimum order requirement
• Fast turnaround and U.S.-based delivery
• Free structural mockups and custom dielines
• Eco-friendly and recyclable material options
• Dedicated support from design to shipment

Get a Free Quote Today

Pack heavy, ship smart, and protect more with double-layer strength. Call 0000 or email us now to start your double wall corrugated box project with Custom Boxes Lab—where protection meets performance.

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.