Custom Suitcase Boxes

Construction, Board and Handle Options

Light kits are usually made from folding boxboard of around 350 gsm. It prints sharply, folds flat for storage and is simple to assemble at a packing table. For heavier contents, or boxes that will be carried around all day, E-flute corrugated board adds stiffness and stops the handle tearing at the slot.

Handles can be integrated, where two flaps meet at the top and lock together to form a grip, or added, where a card strip or ribbon is fixed to the lid. Integrated handles are faster to pack; added handles look more like real luggage. A tuck closure or a small locking tab keeps the lid shut when the box swings.

If the contents are a set of small items, an insert with cut-outs holds each piece in place. It stops a paint pot rolling into a book, and it gives the opening moment a more organised, gift-like look. Our guide to board and card types explains how each board copes with a loaded handle.

Printing the Suitcase Look

This is a box where the artwork can be playful. Many designs use a leather or canvas texture, printed stitching, straps and stickers from imaginary destinations. Others keep it clean with a solid brand colour and a simple luggage tag carrying the logo. Both approaches work because the shape already says suitcase.

Full-colour printing covers every panel, and printing inside the lid adds a surprise, such as a map, a game or a welcome message. A gloss lamination makes bright children's designs pop and wipes clean easily; matt lamination suits more grown-up gift kits. Spot UV on the printed buckles or labels gives a subtle tactile detail. To see how gloss, matt and spot UV compare, read our comparison of print and finish options.

Inserts and Extras That Lift the Unboxing

Once the case is open, the inside is where the impression is made. A printed tray with shaped cut-outs presents each item in its own spot, so a set of nail polishes, a toy figure and a puzzle all look intentional rather than tipped in. For softer contents, coloured tissue or paper shred fills the gaps and stops movement.

Small extras add to the travel theme without much cost. A printed luggage tag tied to the handle can carry a name, a table number or a message. A sticker seal across the lid shows the box has not been opened. A booklet or instruction card can be printed in the same style as the outside, so the whole kit feels like one designed piece.

If the box is going to be reused, which children often do with suitcase boxes, choose a slightly heavier board and a lamination so it survives being opened and closed many times. A box that ends up on a bedroom shelf keeps your brand in sight for months. If you would rather keep the contents on show, window boxes with fitted lids give a similar keepsake feel.

Getting the Size Right

Lay out everything that will go inside, as it will be packed, and measure the length, width and height of the group. Then add space for an insert if you need one and for any tissue or shred. Remember the handle sits above the lid, so if the boxes will be stacked in a carton or on a shelf, include that height in your planning.

For favours and samples, a slim case around 40 to 60 mm deep looks the most like real luggage. For kits with books or bottles, go deeper and consider corrugated board. If you are unsure, send us the item list and we will suggest a size and show it on the proof.

Think about how the boxes will travel to the venue as well. Assembled suitcase boxes take up a lot of room, so most customers fold them on site. If you need them ready-made, we can advise on how many fit into a standard outer carton so you can plan transport and storage before the day.

Ordering Suitcase Boxes for a Launch or Event

Suitcase boxes are supplied flat and folded up on site, so check who will be assembling them and how many are needed per hour. Integrated handles and auto-lock bases speed packing considerably if you are filling a large batch before an event.

We send a free design proof first, then production takes 4 to 7 working days after approval. Delivery is free and tracked to UK mainland addresses. If anything arrives misprinted or damaged, tell us within 10 days and we will reprint or refund it. Share your contents, rough size and quantity and we will send a custom quote within one working day.