Custom Corrugated Boxes

What corrugated board is

Corrugated board has a wavy inner layer called the flute, glued between flat sheets called liners. The arches of the flute resist crushing, so the board stays stiff without much weight. Single wall board has one fluted layer; double wall board has two, for heavier or more fragile items.

Common flute types

• E-flute: a thin flute with a smooth surface that prints well. It is common for mailer boxes and retail boxes that also ship.
• B-flute: thicker than E-flute, with more cushioning and stacking strength.
• Double wall (such as BC): two flute layers for heavy products and larger shipping cartons.

When to choose corrugated

Choose corrugated when the box has to survive shipping: e-commerce orders, subscription boxes, wholesale cartons and heavier products. A printed corrugated mailer can double as the unboxing moment, so many direct-to-consumer brands use one box for both protection and presentation.

Liners, printing and finishes

Corrugated comes with a brown kraft liner or a white liner. White gives brighter color; kraft gives a natural look. Printing can go on the outside, the inside or both. Inside printing is a popular way to add a message or pattern that the customer sees when the lid opens. Matte or gloss coatings, spot color and foil are options on many styles.

Design tips

• Measure the product and add room for any insert or padding before choosing the box size.
• Keep fine text away from fold lines and edges.
• Pick the flute based on product weight and how far it travels, not only on looks.
• Consider custom inserts to stop items moving inside the box.

How ordering works

Send us the style, inside dimensions, quantity, print sides and delivery location. We reply with pricing, help with artwork on the dieline, and send a digital proof before print. Our production partner makes and ships the boxes, and we remain your contact throughout.