How Are Rigid Boxes Made?

Most of the processes are either done by machine or hand or various combinations of the two

Rigid boxes start out as sheets of what is called chipboard (or greyboard or plainboard) which is like the color of newspaper (there is also an option for colored chipboard that will give color to the inside of the box). Cutting and scoring dies are used to cut the chipboard to its correct shape and size, while the sides of the box are scored (not cut all the way through to facilitate folding).

Rigid Box Scored and Cut

The box sides are folded up at the score areas to complete the box form. Tape is then applied to secure or “stay” the sides using a machine called a quad stayer.

Rigid Box Taped on the Sides

The wrap is prepared by having it printed-on (if desired) then trimmed or “mitred” to perfectly fit the box. The box is then placed on the wrap where glue is used to adhere the two together.

Wrap Glued to the Outside of the Rigid Box

Wraps can be all types of paper or fabrics with a staggering array of textures and colors and finishes (i.e. high gloss or matte) including embossing, foil stamping and flocking (adding sparkles). For a look at different kinds of custom box embellishments click here.

Rigid Box Base is Completed

The wraps can also be either tightly or loosely wrapped around the box. Traditionally, when rigid boxes were all hand-made, the wraps were always loosely wrapped. Now the norm is to wrap the box tightly. People can still usually opt to have their rigid boxes with loose wrap; it gives the box an air of being hand-made and therefore more expensive and luxurious.