How are Rigid Boxes Made?

Rigid boxes are considered one of the more premium custom boxes on the market. Here, we break down how a rigid box is made so that you can understand the processes behind creating these premium boxes.

Step 1: Sizing

Rigid boxes start off as a flat paperboard, usually at least 800gsm thick, where it is cut and scored to its correct size. The dotted lines show where the paperboard will then be folded up.

Rigid Box Production Process Flat Paperboard

Step 2: Folding

The sides of the box are folded up and secured to form the base shape of the box. Once folded, you have the basic skeleton of your packaging.

Rigid Box Production Process Paperboard Folded Up

Step 3: Printing

A design is printed onto a piece of paper (the wrap), gets laminated, and other add-ons such as foil stamping or embossing is also done now. The wrap is then automatically glued to the shape of the box.

Step 4: Wrapping

The wrap covers your box tightly and brings your rigid boxes to life. Voila!

Rigid Box Production Process Finished Product

Rigid Box Examples

Here are a couple of rigid box examples with print on just the outside of the box, and print on both the outside and inside. Here's more information that explains what is meant by printing on one or two sides of your box.