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Custom
Rigid Boxes

Name: Custom Rigid Boxes
Brand: Packwire
SKU: RIGID-BOX
Availability: InStock
Rating: 4.9 (12 reviews)

Also known as: Set-up Box · Box and Cover · Gift Box · Telescoping Box

4.9 (12 reviews)

Premium printed rigid boxes your customers keep. Nine stock sizes or any custom size, designed online with instant pricing.

A stack of custom printed rigid boxes by Packwire in bold colors and patterns

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Box Size (inches)

Need a size that is not listed? Choose Custom size and we will .

Quantity

Available in 500, 1,000, 1,500 and 2,000 units

Shipping ZIP code

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$2.54/unit

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Custom rigid phone boxes with a red gradient print, packed in foam peanuts

What is a Rigid Box?

A rigid box is a two-piece box, a tray and a lift-off lid, each made from thick chipboard wrapped in printed paper. It arrives assembled and never folds flat, which is why it feels the way it does in the hand. The same box is called a set-up box, a box and cover, a gift box or a telescoping box, and it is the box a phone, a watch or a bottle of perfume comes in.

Packwire rigid boxes are built on 50 pt chipboard, about 1/16 inch thick and thicker on larger sizes, wrapped in 80 lb paper that is litho printed in full color and laminated to the board. They come in nine stock sizes or any custom size, from 500 boxes up.

Rigid Box specifications
Box style	Two-piece set-up box, tray and telescoping lid
Board	50 pt chipboard (1.27 mm), thicker on larger sizes. Dense recycled board that holds its shape
Wrap	80 lb litho paper, printed in full color and laminated to the board. White Board only
Inside	Unlined board with the wrap turned in over the edges. Printed or colored lining and inserts by quote
Holds	Retail and gift products. Ships inside an outer carton
Closure	Lift-off lid, ¾ to 2½ inches deep depending on the size
Printing	Full color on the wrap, outside. Foil stamping and other finishes by quote
Sizes	9 stock sizes from 3.5" × 3.5" × 1" to 12" × 8" × 2" (inside dimensions), custom sizes by quote
Minimum order	500 boxes, with short runs by quote
Production	About 30 calendar days after proof approval, plus transit
Arrives	Assembled, ready to fill
Made in	North America, primarily in the USA, within the USMCA zone

Custom printed rigid boxes on bright yellow steps, a hand holding up a white box as confetti falls

Why brands choose custom Rigid Boxes

Some products deserve a box that stays. A custom rigid box has weight, square corners and a lid that lifts with a little resistance, and all of that registers before your customer has read a word. It is the packaging of phones, watches, perfume and spirits because it tells the buyer the thing inside was worth protecting, and it keeps telling them from the shelf or the drawer where it ends up.

That second life is the point. A printed mailer is opened and recycled. A rigid box is kept, used for the product or for something else, and your brand sits on it for years. For launches, gift sets, welcome kits, subscription keepsakes and anything sold on a counter, it is the box that earns its price back in how the product is remembered.

A table of custom rigid boxes in different sizes, colors and prints

Custom Rigid Box sizes and prices

Nine stock sizes run from a 3.5 × 3.5 × 1 inch box for a ring or a pair of earbuds to a 12 × 8 × 2 inch box for apparel, books or a gift set. Pick the closest one and the quote card prices it on the spot. Need a different footprint, a deeper lid or an odd shape? We make custom sizes to order. Choose Custom size in the quote card, tell us the inside dimensions and the quantity, and our team quotes it as soon as possible.

Sizes are inside dimensions of the tray, written length × width × depth, and each size comes with a lid between ¾ and 2½ inches deep. The board and wrap add about 1/8 inch to each outside dimension, and the lid sits a little proud of the tray by design.

Custom rigid boxes cost from $2.54 per box at the largest quantities to between about $4 and $10 per box at the 500-box minimum, depending on size. A 10 × 7 × 2.75 inch rigid box is $9.10 each for 500 and $5.73 each for 2,000. The table shows all nine stock sizes at those two quantities, priced with full-color print, whatever your artwork covers. Click a size to open it in the designer.

Popular Rigid Box sizes with the unit price at the minimum order and at 2,000 boxes
Size (L × W × D, inside)	500 boxes	2,000 boxes	Open in the designer
3.5" × 3.5" × 1"	$4.95 each	$2.54 each	Design this size
5" × 5" × 1"	$5.30 each	$2.76 each	Design this size
5" × 5" × 2"	$6.21 each	$2.97 each	Design this size
6" × 4" × 1"	$8.05 each	$6.08 each	Design this size
7" × 4" × 2"	$8.68 each	$6.36 each	Design this size
8" × 5" × 3"	$8.40 each	$5.86 each	Design this size
9" × 9" × 2.5"	$8.53 each	$5.93 each	Design this size
10" × 7" × 2.75"	$9.10 each	$5.73 each	Design this size
12" × 8" × 2"	$9.53 each	$7.12 each	Design this size

Need a size that is not on the list? Choose Custom size in the quote card above, or request a quote with the inside dimensions and the quantity. Custom sizes are made to order.

How custom Rigid Box pricing works

A rigid box is priced for what it is, a box that is cut, taped and wrapped on dedicated machines, with an operator feeding and finishing every piece. There are no printing plates to buy and no tooling, so the price is the board, the paper, the print and that labor, and it steps down as the run gets longer. Full-color print is included whatever your artwork covers. A small logo on white and a pattern over every face cost the same.

Our standard minimum is 500 boxes. Need fewer, for a launch, a pilot run or a round of VIP gifts? Short runs are case by case. The machine setup and the hands-on work are the same for 50 boxes as for 500, so a short run costs considerably more per box. We will tell you the number plainly before you decide.

Size. The price follows the board and the wrap the two pieces are cut from, plus the time it takes to wrap them. The dieline section below shows what goes into a box.
Quantity. Order 500, 1,000, 1,500 or 2,000 boxes in the designer. Above 2,000, or below 500, request a quote.
Finish. The standard wrap is printed paper with a smooth surface. Matte, gloss or soft-touch coatings, selective varnish, and foil stamping on runs above 3,000 boxes are quoted on request.
Lining. The inside is unlined board by default. A printed or colored paper lining over the inside of the tray and lid is a custom option, quoted with your order.
Inserts. Board, foam or corrugated inserts that hold the product in place are cut to your box and quoted on request, from 500 units.

Custom rigid jewelry box with its lid off and a bracelet on crinkle paper inside

Rigid Box materials

Two materials make a rigid box, and they do different jobs. The core is 50 pt chipboard, a dense board made largely from recycled fiber, about 1.27 mm thick and thicker on our larger sizes. It gives the box its weight and keeps the corners square for years. The skin is an 80 lb litho paper, 118 gsm, which carries the print and wraps around the board with mitred corners and a margin turned in over every edge.

The board itself is never printed. Everything you see is the wrap, which is why a rigid box can take fine type, smooth gradients and finishes that corrugated board cannot.

Want a different paper or a textured wrap? Those are custom options. Request a quote with your size, quantity and the look you are after.

A hand holding up a white custom rigid box with a printed lid

Built to be kept

A rigid box protects what is inside it on the shelf, in the bag and on the dresser. The board does not crease, the lid holds the contents in place, and the wrap takes handling without showing it. Add a fitted insert and a phone, a candle or a bottle travels inside it without moving.

What it is not built for is the parcel network on its own. Wrapped corners scuff against sorters and belts, so a rigid box ships inside an outer carton, plain or printed, with a little void fill around it. Sized right, the shipping box costs a fraction of what is inside it.

Green custom rigid box with a gold printed lid and a patterned wrap on the lid walls

Custom printed Rigid Boxes, litho on the wrap

Rigid boxes are the one Packwire box that is not printed directly on the board. Your artwork is litho printed on the paper wrap, on an offset press, in full CMYK color. That is the same process as a hardcover book jacket or a premium carton, and it holds fine type, hairline rules, photographs and smooth gradients that direct-to-board printing cannot.

The printed sheet is then laminated to the chipboard, so color sits on a smooth surface rather than on flutes, and edges stay crisp around every corner. Bring your logo and your website's palette to the box, with print quality that reads as premium from the first box in the run to the last.

Artwork. Vector files (PDF, AI or EPS) or raster files at 300+ dpi, in CMYK, with a quarter-inch bleed so the print carries around the corners and under the turn-ins. See the artwork guidelines.
Color. Your brand colors, on the box. Litho printing lands close to Pantone® references, and your account manager emails a proof before anything prints. Coatings, selective varnish and foil stamping are quoted on request, foil on runs above 3,000 boxes.

Open custom rigid box with a tablet inside and its printed lid beside it

Lined inside, on request

Open a standard rigid box and the inside shows the wrap turned in over the top edge of each wall, with the board below it. Most brands fill that space with tissue, crinkle paper or an insert, and it reads as a finished box. Want more? A lining covers the inside of the tray and lid with a printed or colored paper, so the box is yours inside and out, in a brand color, a pattern or a message under the lid. Ask when you order and we will quote it with your run.

Custom black rigid box with a gold candle inside and a lid printed with copper waves

How a Rigid Box is made

Every rigid box starts as two flat sheets of chipboard, one for the tray and one for the lid. Each sheet is cut to size and scored around the base so the four walls fold up square. The corners are held with stay tape, a strong paper tape run down each corner joint, and that taped tray is the box's skeleton. The printed wrap is glued and laminated around it on a wrapping machine, with an operator placing each tray and checking every corner, pressed onto the walls and the base, mitred at the corners so nothing bunches, and turned in over the top edge of every wall. The lid is built the same way, a touch larger so it telescopes over the tray. A lining or an insert goes in last, and the box leaves the plant assembled.

Production dieline for a 10 × 7 × 2.75 in rigid box: the printed wrap (solid line, mitred at the corners) around the scored chipboard of the tray and the lid (grey edges, dashed base scores), seen from the printed side. The wrap's margin turns in over the free edge of each wall. Arrows mark the top of the artwork on each wall.

The board and the wrap

Two sheets go into each piece. The chipboard blank is the base plus a wall on every side, so for a tray of length L, width W and depth D it measures L + 2D by W + 2D, scored around the base. The wrap is that blank plus the turn-in all round, about L + 2D + 1¼ by W + 2D + 1¼ inches, with the corners mitred. A 10 × 7 × 2¾ inch tray takes a board about 15½ by 12½ inches and a wrap about 16¾ by 13¾. The lid is built the same way from a shallower, slightly larger pair of sheets. Those four sheets, and the machine time and labor that join them, are what the price follows. Need the production files for a size? Request a dieline and we will email them to you.

Where the print goes

Everything you design prints on the outside of the two wraps, which is the view shown here. The tray's wrap carries the bottom and the four walls, the lid's wrap the top and the lid's four walls. On the tray the artwork on each wall reads away from the base, with its top at the turn-in, because the walls stand up from the base. On the lid it reads toward the lid top, because the lid's walls hang down from it. The turn-ins show inside the box as a border of your print along each edge. The rest of the inside is unlined board unless you add a lining.

Rigid Box parts, their names in the 3D designer, and what each one does
Part	In the 3D designer	What it does
Base	Bottom	The floor of the tray, length by width. The walls fold up from its four scores.
Walls	Front, Back, Left, Right	The four sides of the tray, as deep as the box. Their outside is the printed wrap, and it turns in over their top edge.
Lid top	Top	The face your customer sees first. The lid is cut a little larger than the tray so it slides over it.
Lid walls	Front, Back, Left, Right (lid)	The sides of the lid, ¾ to 2½ inches deep depending on the size. Their artwork reads toward the lid top.
Turn-ins	No face of their own	The margin of the wrap beyond the board, about 5/8 inch, glued over the free edge and down the inside of each wall. Print carries onto it as bleed.
Mitred corners		The wrap is cut at 45 degrees at each corner so it folds around the walls without bunching, and the corner joint of the board underneath is held by stay tape.
Lining	By quote	An optional second paper covering the inside of the tray and lid, printed or in a solid color.

Custom rigid boxes on yellow steps, a black lid with copper waves and a small printed box

Design custom Rigid Boxes online in minutes

Pick a stock size, upload your logo and graphics, and the 3D designer shows the finished box, tray and lid, from every angle while the price updates beside it. Save the design to your account, and when it is right, order the run. Finishes, linings and inserts are added by our team when you ask for a quote.

Step 1DesignPick a stock size and quantity, then build the artwork in the 3D tool or upload your own. The price updates as you go, and it does not change with how much you print.
Step 2ProofYour account manager emails a 2D proof once our prepress team has checked resolution, bleed and color. Revisions are free until you approve.
Step 3ProductionAbout thirty calendar days after approval. The wrap is litho printed, the board is cut, scored and taped, and each box is wrapped on a machine, with an operator handling every piece. That care is where the time goes.
Step 4DeliveryBoxes arrive assembled, packed in cartons, by parcel or on a pallet depending on the run, with about one to seven days in transit. Enter your ZIP code in the quote card for the shipping cost and an estimated delivery date.

Rigid Boxes made close to home, on recycled board

The chipboard at the heart of every Packwire rigid box is made largely from recycled fiber, and the finished box is paper through and through, so it recycles with cardboard when it finally reaches the end of its life. That end tends to be a long way off. A rigid box is kept, reused and passed around, which is the most sustainable thing packaging can do.

We make rigid boxes close to home, in North America and primarily in the USA, with people you can reach on the phone. That keeps lead times and freight down, and it keeps quality the same from one run to the next.

Custom Rigid Box questions

What is your minimum order quantity (MOQ)?

The minimum order for custom rigid boxes is 500 boxes, priced live in the quote card at the top of this page at 500, 1,000, 1,500 and 2,000. Need fewer? Short runs are case by case, at a much higher price per box, because the machine setup and the hands-on work are the same for 50 boxes as for 500. Request a quote and we will tell you plainly whether it makes sense for your project.

How long is your production time?

Custom rigid boxes take about 30 calendar days to produce, longer than our corrugated boxes, because every box goes through several machine steps with an operator at each one. The clock starts when you approve your online proof. Transit adds roughly one day to a week, so plan on five to six weeks door to door. Enter your ZIP code in the quote card to see an estimated delivery date, and confirm exact dates with us before you plan a launch.

Need it sooner? Contact us with your timeline and we will tell you what is possible.

Where are your boxes manufactured?

Our rigid boxes are made in North America, primarily in the USA and always within the USMCA zone, which covers the US, Canada and Mexico. Keeping production on this side of the ocean means shorter lead times, fewer supply chain surprises and the same quality from one order to the next.

Are Rigid Boxes safe to ship?

Not on their own. A rigid box is presentation packaging, and its wrapped corners and edges scuff in a parcel network. Ship it inside an outer carton, plain or printed, sized to leave a little room for void fill, and it arrives looking the way it left you.

Why is shipping more expensive for Rigid Boxes?

Rigid boxes arrive assembled, so they ship at full volume rather than flat, and carriers charge by size as well as weight. Most orders travel on a pallet. The quote card at the top of this page prices shipping for your ZIP code before you order. On the other side of the ledger, there is no assembly time at your end.

Do you offer foil stamp?

Yes, on rigid boxes at quantities above 3,000. Foil stamping is a separate process from the litho print, so it is quoted rather than priced in the designer. Contact us with your artwork and quantity.

Can I order a physical sample?

Rigid box samples are made case by case, because each one needs its own machine setup. Contact us with your size and artwork and we will tell you what we can do and what it costs.

How do I assemble my boxes?

You don't. Custom rigid boxes arrive fully assembled, tray, lid and any lining or insert you ordered. Unpack them, fill them and put the lid on.

All questions and answers

What customers say about our Rigid Boxes

Rigid boxes we made, in the words of the people who ordered them. Packwire is rated 4.8 out of 5 on Google. More reviews.

Amy Burrows

Lucked into finding Packwire for a low quantity need for custom boxes, and so glad I found them! Phil was incredibly helpful from the start, guiding us on art files and making sure all order details were perfect. He was always quick with email responses and information, all the way through order delivery. Will definitely use them again! Adding an update August 2024 to say again how AMAZING Packwire is. They helped me with a quick turn on a reorder, and the boxes are perfect! Thanks Phil and the Packwire team for such great service and quality product!

Margaret Lepper

Great place to do business with. my boxes are beautiful. Zach was so nice. He made sure the images on my boxes were just right. They are exactly how I wanted them to look. Will definitely buy more.

Jessica Medeiros

My custom boxes came out beautiful! I highly recommend this company. They did a fantastic job!

Penny Schaaf

So pleased with my custom boxes. The communication and quality of the finished product was phenomenal! I can't wait to work with Packwire again, and will recommend them to my friends as well.

Shawn Thomas

Great quality, on time, excellent customer service. First time trying packwire and they really came through, assisting in each step of the way. Highly recommend.

Laura Godoy

Excellent customer service, boxes arrived in perfect condition. Will definitely work with their team again.

Ready to give your product a box worth keeping?

Pick a stock size, upload your artwork and watch your custom rigid box take shape in the 3D designer with the price beside it, litho printed on a paper wrap, built on thick chipboard and made close to home in North America. Order five hundred or two thousand with no plates or tooling to pay for, and ask us about short runs, linings and foil. A few weeks from now your customers are lifting a lid with your name on it.

Design your Rigid Box