Flat Cardboard Box

Ideal for Low-Profile Products and Smart Shipping

Flat cardboard boxes are perfect for:

• Apparel and T-shirt packaging
• Books, documents, and portfolios
• Calendars, photo prints, or posters
• Slim electronics like keyboards and accessories
• Subscription kits or presentation materials

Durable Materials That Handle It All

We craft each box using strong, sustainable materials designed to protect thin or flat products from bending, tearing, or creasing.

• Corrugated cardboard – Tough and crush-resistant for transit
• SBS paperboard – Great for lightweight retail products
• Kraft cardboard – Eco-friendly and ideal for rustic or minimalist branding
• Folding cartons – Easy to ship flat and assemble fast

Fully Custom Sizes and Structures

We tailor every box to fit your product perfectly.

• Choose your box depth, width, and length
• Self-locking or tuck-flap styles available
• Add sleeves, bands, or inner trays as needed
• Perfect-fit inserts for added security during shipping

Printing That Packs a Punch

Your brand deserves packaging that stands out, even with minimal dimensions.

• Full-color CMYK or spot Pantone printing
• Matte, gloss, or soft-touch finishes
• Embossing, debossing, and foil stamping
• Inside print for product instructions or messaging

Smart Add-Ons for Extra Impact

Elevate your flat cardboard box with stylish and functional extras.

• Tear strips or thumb notches for easy opening
• QR codes linked to product videos or digital catalogs
• Custom stickers, wrap bands, or belly bands
• Eco-friendly sealing tape with your logo

Why Custom Boxes Lab?

Trusted by 5000+ brands, we combine form, function, and speed for packaging that performs.

• No order minimums—perfect for small runs or scaling
• Free dieline and print setup
• U.S.-based fast production and shipping
• Responsive design support from start to finish
• Sustainable printing and materials available

Get a Free Quote Today

Design a flat cardboard box that checks every box—protection, presentation, and performance. Reach out to our packaging experts now at 0000 or email us to get started with a free quote and dieline assistance.

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.