Production video
Printing the customer’s design
The one-colour artwork is printed onto the flat board before the box is cut and assembled.
Please note that all box dimensions quoted refer to the internal measurements of the box.
Please note that all box dimensions quoted refer to the internal measurements of the box.
Custom Box Case Study
From Customer Requirements to a Finished Custom Printed Box
This case study follows the complete journey of a made-to-measure cardboard box, from the customer’s original order requirements through design, material selection, printing, manufacturing, assembly and the final finished result.
The customer’s requirement
The customer required a strong, made-to-measure printed box for a product that needed improved protection during handling, storage and transportation.
They selected an overlapping-flap box style, Tuff Wall material and a single-colour printed finish in natural brown kraft board.
Project objectives
- Create a box around the required internal dimensions
- Provide extra-heavy-duty protection
- Improve the strength of the top and bottom closure
- Apply clear single-colour branding
- Supply a professional finished box ready for use
How we received the customer’s order
The customer used our online Custom Box Calculator to select the box style, material, printing option, dimensions and other requirements.
The original box specification
This order information gives our production team the essential details required to manufacture the box accurately. It confirms the selected style, material, print option, colour and internal dimensions.
Box style
0203 overlapping-flap box
Material
Tuff Wall – extra-heavy-duty Double Wall
Printing
One-colour printed design
Internal dimensions
47 × 34 × 37 cm
The complete box manufacturing journey
Every made-to-measure box passes through a structured process to ensure that the dimensions, material, print and finished construction meet the customer’s requirements.
1
Order review
We reviewed the selected box style, material, dimensions, print requirements and intended packaging application.
2
Artwork preparation
The supplied logo or print design was checked and positioned for the required box panels.
3
Material selection
Tuff Wall board was selected to provide extra-heavy-duty Double Wall protection and improved stacking strength.
4
Printing the board
The customer’s branding was applied directly to the flat cardboard material using the selected print colour.
5
Cutting and creasing
The board was accurately cut and creased to create the required 0203 overlapping-flap box structure.
6
Assembly and inspection
The box was assembled and checked for fit, print position, structural strength and overall presentation.
Behind the scenes
These images and videos show the different production stages involved in turning flat corrugated board into a finished custom box.
Flat Packed Box video
Assembling the box
The finished flat blank is folded into shape so the structure, overlapping flaps and finished dimensions can be inspected.
Final quality check
The completed box is checked for print quality, dimensions, structure and overall finish.
Swipe sideways on mobile to view all production images and videos.
The finished result
The completed box combined heavy-duty protection, accurate internal dimensions and clear printed branding.
A strong and professional custom box
The finished 0203 box provided the customer with a robust packaging solution designed around their exact requirements.
- Made to the required internal dimensions
- Extra-heavy-duty Tuff Wall material
- Overlapping flaps for improved strength
- Clear one-colour printed branding
- Professional natural kraft finish
- Ready for packing, storage and transportation
What the customer gained
Better product fit
The made-to-measure dimensions reduced unnecessary empty space and helped hold the product more securely.
Improved protection
Tuff Wall material and overlapping flaps provided stronger structural support during handling and transport.
Professional branding
The printed finish helped turn a transit box into a more recognisable and professional branded package.
Need a custom box made for your product?
Use our online box calculator to choose your box style, material, dimensions and printing requirements, or contact our team for help with a more demanding packaging project.