Guide / Materials & board grades / Chapter 3.6
Rigid board and wrapping papers.
Rigid boxes feel solid in the hand because they're built from thick board wrapped in printed or textured paper. Here's what they're made of and how the materials affect the look and cost.
The short answer
A rigid box is made from thick, stiff board (traditional rigid boxes don't fold flat, while collapsible rigid boxes are made to ship flat), wrapped in a thin decorative paper. The board gives the box its strength and weight, and the wrapping paper gives the colour, texture and print. Rigid boxes are popular for jewellery, cosmetics, gifts and premium products. Our custom rigid and magnetic boxes start from 250 units, with foil printing in black, white, gold, silver or rose gold.
How a rigid box is made
Unlike a folding carton or mailer box, a rigid box is made as a finished shape. The board is cut, the corners are joined, and a wrapping paper is glued over the outside and folded in over the edges. A lid, a hinged lid or a magnetic flap is made the same way.
Because the box is built rather than folded, it keeps its shape, opens smoothly and feels substantial. It's also bulkier to store and ship, since most rigid boxes arrive already made up.
The materials
The board
Rigid boxes use a thick, dense board, usually grey or with a coloured surface. It's much thicker and stiffer than the paperboard used for folding cartons, which is what gives a rigid box its solid feel.
The wrapping paper
The wrap is where the design lives. It can be a plain coloured paper, a textured or embossed paper, or a printed paper. Textured wraps give a premium feel without complex printing.
Decoration
Foil printing is the most popular way to add a logo to a rigid box. Our foil colours are black, white, gold, silver and rose gold.
Inserts
Rigid boxes often have an insert to hold the product in place, such as a card, foam or a fitted tray.
Rigid boxes at PackQueen
These are two different products, with different timing.
| Detail | Custom rigid boxes | Custom collapsible magnetic boxes |
|---|---|---|
| Minimum order | From 250 units | From 250 units |
| Lead time | Express 15–20 working days, standard 6–8 weeks | 4–6 weeks |
| Logo | Foil in black, white, gold, silver or rose gold | Printed, with foil available as an extra |
| Arrives | Made up | Flat, assembled by you |
What it means for you
The same question, answered for where your business is today.
Choose your stage at the top of the page to open the advice for you.
Start-up · under 100 units
Custom rigid boxes start from 250 units, so at the start, stock rigid boxes with a sticker or ribbon give a premium feel without a custom run.
Stock rigid and magnetic boxes in a neutral colour work well with a foil-look sticker.
Growing · 100 to 2,499 units
A custom rigid box with a foil logo is a big step up for gift and premium products. Plan around the lead time, especially before Christmas.
Try this: choose the box size and insert first, then the wrap and foil colour.
Enterprise · 2,500 units and more
Specify the board, wrap, foil colour, insert and packing for each box, and order well ahead of peak seasons. Rigid boxes take more storage space than flat-packed boxes.
Allow for the standard 6–8 week lead time when planning large runs.
Common mistakes
- 1Leaving it too late. Rigid boxes have longer lead times than folding boxes. Order early, especially for peak seasons.
- 2Forgetting storage space. Most rigid boxes arrive made up, so they take far more space than flat boxes.
- 3Overcomplicating the design. A textured wrap and a single foil logo often look more premium than busy artwork.
- 4Skipping the insert. A product that slides around in a rigid box feels less premium. Plan the insert with the box.
Rigid box questions
What is a rigid box made of?
What's the minimum order for custom rigid boxes?
How long do custom rigid boxes take?
What foil colours are available?
Can rigid boxes be posted?
Keep reading
Shop rigid boxes
Planning a premium box?
Send us your product, quantity and timing. Our Melbourne team will recommend the box style, wrap and foil, usually within 1 business day.