Die-Cut Boxes
Bespoke die-cut corrugated boxes built from FEFCO styles or a structure designed from scratch.
Get a Custom QuoteThe details
| Structure | FEFCO styles or fully bespoke die-cut design |
|---|---|
| Tooling | CAD dieline built free by our structural team |
| Board | E-flute, B-flute or C-flute corrugated |
| Features | Locking tabs, built-in dividers, cradles, hang panels |
| Fit | Holds product by shape — no loose void fill |
| Printing | Flexo or digital, full color or single hit |
| Sampling | Cut sample to test before the full run |
| Proofing | CAD dieline plus 3D render before production |
| MOQ | 12 |
| Lead time | 2 weeks (faster turnaround available with express shipping) |
Die-Cut Boxes
Die-cut boxes exist for the products a rectangle cannot flatter: awkward shapes, fragile parts, kits with components that need to stay apart, displays that need to fold up in one motion. We start from the FEFCO library of proven corrugated constructions — wrap-arounds, five-panel folders, trays with locking corners — or design a structure from scratch around your product’s actual geometry. Either way, the box is cut, scored and slotted as one engineered piece.
The payoff is fit. A die-cut structure can hold a product by its shape, with built-in dividers, cradles and locking tabs replacing loose void fill entirely. Nothing shifts in transit, nothing needs bubble wrap, and unpacking feels like opening an instrument case instead of digging through packing peanuts. Hang panels, windows and presentation flaps can be cut into the same sheet, so structure and merchandising come from a single die.
Our structural team builds the dieline free of charge. Send the product or its dimensions and we return a CAD dieline, a 3D render and — before you commit to the full run — a cut sample you can hold, fold and drop-test. Print is flexo or digital in full color or a single hit, in E-, B- or C-flute matched to how much protection the shape has to provide.
Die-cut boxes suit products that stock boxes treat badly — electronics, glassware, kits, parts, anything oddly proportioned. Free custom artwork within 24 hours and unlimited revisions until the structure is right. Get a quote for custom die-cut boxes and let our team engineer the shape for you.
Who this style suits
Electronics & fragile goods
A structure that cradles the product by its own shape protects better than any amount of loose fill.
Kits & multi-part products
Built-in dividers keep components separated and presented, so the box does the organizing for you.
Awkwardly shaped products
Long, flat, round or lopsided — a bespoke dieline fits the product instead of forcing it into a cube.
Die-Cut Boxes: quick answers
What is the minimum order?
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Can the box replace foam and void fill?
Get a custom quote for the die-cut boxes.
Send your logo and a rough quantity — free mockup back within one business day.
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