Custom Die-Cut Boxes
Updated
Custom die-cut boxes are boxes cut from a flat sheet with a steel-rule die that follows a custom outline, allowing unusual shapes, windows, tabs, handles and built-in inserts. Vorex makes die-cut boxes to your exact design for brands across the USA and Canada.
Die-cut box styles
3 options. Every product is made to your size with your artwork.
What does die cut mean?
Die cutting is the process of pressing a shaped blade, called a die, through a printed sheet of board to cut the outline and score the fold lines in one step. The flat result is folded into a box. The plan for that cut is the dieline, a flat drawing that shows cut lines, folds and glue areas. Because the die follows any outline, die cutting makes custom shapes possible without hand trimming.
When to choose a die-cut box
Choose a die-cut design when a standard box does not fit the product or the experience you want: a window shaped like your logo, a carry handle cut from the same sheet, a lock tab closure, a product that needs a cradle, or a box that unfolds to reveal its contents. Die-cut features can also replace separate inserts, which keeps packing simple.
Materials and finishes
Die cutting works on SBS paperboard, a smooth bleached board for bright print; kraft board, which is unbleached; and corrugated board, including E-flute, a thin fluted board common for mailers. Thicker boards need simpler cuts. Lamination, foil and spot UV are applied before the sheet is cut.
Design tips
- Start from a dieline: we can supply one sized to your product.
- Keep a safe zone: hold text and logos away from cut and fold lines.
- Add bleed: extend background color past the cut line so edges stay clean.
- Avoid very fine details: thin strips of board tear easily.
How ordering works
Send us your size, quantity, material and artwork through the quote form. We reply with pricing and options. Our team helps set your artwork on the dieline, and you receive a digital proof before print. Nothing goes to production until you approve it, and our production partner makes and ships the finished boxes to you anywhere in the USA and Canada.
Get a free quote in minutes
Size, quantity and email. We reply with pricing and options.
Custom Die-Cut Boxes: common questions
What is a dieline?
What is the difference between a die-cut box and a regular box?
Can a die-cut box replace a separate insert?
Do I need to provide my own dieline?
How do I order custom die-cut boxes?
Ready to see your brand on a box?
Send us your size and quantity. We reply with pricing, material options and a digital proof of your design.
