Custom Double-Wall Boxes

What is a double-wall box?

Corrugated board is made of a wavy layer, called the flute, glued between flat sheets, called liners. Single-wall board has one flute and two liners. Double-wall board has two flutes and three liners, so it is thicker and stronger. A common pairing is BC-flute, which combines a B flute and a C flute in one board.

When to choose double-wall

Choose double-wall when single-wall boxes are being crushed, punctured or bowed: heavy items, fragile goods such as glass and ceramics, electronics, auto and industrial parts, bulk or wholesale orders and boxes that will be stacked high in storage or on pallets. It is also a good outer box for shipping printed retail boxes so they arrive clean.

Materials and finishes

Double-wall board comes with kraft liners, which are unbleached and brown, or with white liners, which give a cleaner print surface. Print is usually simple: a one or two color logo, handling marks and labels. Strength is often described by an edge crush test (ECT) or burst rating, which our production partner can confirm for your quote. Inserts and dividers can be added to keep items apart.

Design tips

• Size to the product: a box made to your exact size reduces void fill and movement.
• Keep print bold: thick board suits simple artwork over fine detail.
• Add handling marks: "this side up" and "fragile" where needed.
• Tell us the weight: it helps decide the right board.

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.