Rigid Boxes

(also called “Set-Up Boxes”) are a very common type of packaging and they are often associated with luxury products. Rigid boxes are typically four times thicker than an average folding carton and are not usually printed on directly. They are instead wrapped with paper that can be as plain or luxurious as desired.

Rigid boxes, as the name suggests, are rigid and sturdy. Think of the classic “Shoe Box”. If you’ve ever purchased a nice pair of shoes or heels, they will have been packaged in a rigid box. Board games are another classic example of rigid box packaging. iPhones and other high-end electronics use rigid boxes, as do many beauty and high-end food products and spirits, just to name a few.

How Are Rigid Boxes Made?
Most of the processes are either done by machine or hand or various combinations of the two, depending on the specific manufacturer.

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.