Custom Double-Wall Lid Boxes

Board Choices and How They Change the Box

For smaller products we usually make double-wall lid boxes from folding boxboard, either white or kraft. It folds crisply, takes full colour print well and is plenty strong once the walls are doubled. For heavier contents, E-flute corrugated board adds cushioning and stiffness while staying thin enough to fold neatly at the rim.

If you plan to ship the box on its own, without an outer carton, tell us the weight of the contents. We will suggest whether corrugated board is needed and whether the lid should be a full-depth cap that covers the whole base or a shallower lid that shows a band of the base underneath.

Lid Depth, Fit and Sizing

Start with the internal size: length, width and height of the product, plus any insert or tissue that goes in with it. We build the base around those measurements and size the lid a fraction larger so it slides on smoothly without being loose. Remember that the doubled wall takes up room on the inside, so always give us the space you need inside the box, not the outside dimensions you would like.

A full-depth lid hides the base completely and looks like a single block on the shelf. A half-depth lid leaves a visible strip of the base, which is a good place for a contrasting colour or a product name. A shallow lid, only a few centimetres deep, is the easiest for customers to lift off and suits gift packs that are opened in front of someone.

If the box needs to hold several small items, add a card insert or a simple divider. We can cut it from the same board and print it to match. p2 The guide to measuring a product explains inside versus outside figures.

Print and Finish Ideas

The lid carries most of the branding, so put your logo and product name there and keep the base simpler. Matt coating gives a soft, quiet look that suits homeware and stationery. Gloss brings out photographs and bright colour. Spot gloss on a matt lid, foil on a logo or an embossed brand mark adds a tactile detail that customers notice when they pick the box up.

Printing the inner walls in a solid brand colour is one of the cheapest upgrades on this style. It turns the open base into a neat display tray, which helps if the product sits in the box on a shop counter. For kraft board, a single white or black ink keeps the natural surface visible and looks honest and practical. p1 The finishes are compared on the board and finish page.

Setting Up the Boxes on a Packing Bench

The first few boxes take a moment while your team learns the fold order: base panel flat, outer walls up, inner walls down, then press the locking tabs home. After a dozen or so, most people can build one in well under a minute without looking. We send a simple folding guide with your first order and can print small fold marks on the inside of the dieline if that helps new staff.

Because there is no glue, a box that has been folded wrongly can simply be opened out and folded again. That saves waste when you are training someone new, and it means unused stock can be kept flat at the end of a season rather than taking up shelves as built boxes.

For large runs, build a stack of bases and a stack of lids before you start packing products. Working in batches keeps the bench tidy and stops half-folded boxes getting crushed under finished orders. p2 Teams that pack hundreds a day sometimes prefer the glued corners of our six-corner trays that pop up.

Give Us the Inside Size and Let the Walls Add the Rest

The one measurement that catches people out on this style is the wall. Because each side folds back on itself, the doubled board takes 3 to 4 mm from every inside face, so a box ordered by its outside size ends up too small. Measure the product, add the insert or tissue, and send that as the inside size; we build the base round it and size the lid to slide over.

Choose the lid depth from how the box is opened: shallow for a gift unwrapped in front of someone, full depth for a shelf. Say whether the inner walls should carry a solid colour, the cheapest upgrade on this box. The custom quote arrives by email within one working day, from £0.25 for simple sizes.

The free proof shows the flat dieline with the folds and the locking tabs; ask for a plain folded sample too if the style is new to your team. Production takes 4 to 7 working days after approval and the flat bases and lids reach UK mainland addresses by free tracked delivery. Brands that need a divided interior often add boxes with fitted inserts for the premium end.