How Custom Boxes Are Made?


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Custom boxes play a crucial role in product packaging and branding. They provide businesses with a golden chance to present their products in the best way possible while leaving a lasting impression on consumers. In this blog post, we will delve into the fascinating process of how custom boxes are made, exploring the materials used, the printing techniques employed, and the importance of artwork, text, and typography.

What are Custom Boxes?

Custom boxes are packaging solutions tailored to specific products, designed to enhance brand recognition, protect the contents, and create a memorable unboxing experience. These boxes are created with careful consideration of the product’s size, shape, and branding requirements.

Get the Right Material – Paperboard SBS:

To create durable and visually appealing custom boxes, you need to pay due attention to the selection of the right material. Solid Bleached Sulfate (SBS) is a popular choice due to its adaptability and reliability. SBS is a lightweight, yet sturdy, paperboard that offers excellent printability and can be easily cut, folded, and shaped. Its smooth surface provides a high-quality canvas for vibrant graphics and text. The thickness of the SBS used for custom boxes depends on the product’s weight and fragility. 


For heavier and bulkier products or those requiring extra protection, corrugated cardboard is the material of choice. Corrugated consists of three layers: an inner fluted layer between two flat liner boards. This structure provides strength, shock resistance, and insulation properties, making it ideal for shipping and transportation. The thickness of the corrugated material varies depending on the product’s weight and the level of protection required. For example, luxury candle boxes should be designed while keeping the fragile and delicate nature of the candles in mind.

Let’s Move to the Printing Process:

After you select the appropriate material, the next step is the printing process. Various printing techniques are used depending on the desired outcome and budget. Offset printing is a widely used method that produces high-quality results. It involves transferring ink from a printing plate to a rubber blanket. After that, it is transferred onto the custom box. Flexography is another popular technique, especially for large-scale printing. It makes use of flexible relief plates and fast-drying inks. Digital printing is a cost-effective option for smaller print runs, as it eliminates the need for plates and allows for quick turnaround times. These printing methods ensure high-quality graphics, vibrant colors, and sharp details.

Concentration on the Artwork:

Artwork is the visual representation of a brand and plays a pivotal role in custom box design. It includes the logo, colors, imagery, and overall packaging aesthetics that reflect a brand’s unique identity. Designers work closely with businesses to create visually appealing artwork that aligns with the brand’s values and resonates with the target audience. The artwork is carefully crafted to capture attention, stimulate emotions, and leave your customers in awe. Special attention is given to color selection, ensuring consistency with the brand’s color palette and conveying the desired message. For example, custom holographic boxes can be used for attracting customer’s attention in one glance.

Text & Typography:

In addition to the artwork, text, and typography contribute to the overall impact of custom box design. Carefully chosen fonts, sizes, and layouts enhance readability and convey key messages effectively. Brands often incorporate taglines, product information, or even storytelling elements to strengthen their bond with customers. Typography choices should be consistent with the brand’s style guide and complement the overall design. Balancing visual appeal with legibility is crucial to ensure that important information is easily readable.


Custom boxes are more than just packaging. They are an extension of a brand’s identity and an opportunity to leave a lasting impression on consumers. The process of creating custom boxes involves selecting the right materials, utilizing advanced printing techniques, and focusing on artwork, text, and typography. By investing in well-designed custom boxes, businesses can elevate their products, strengthen brand recognition, and provide an exceptional unboxing experience. Remember, custom boxes are not just a means of packaging. Rather, they are powerful marketing tools that can make a significant impact on the success of a brand.

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