Custom Rigid Boxes

About Custom Rigid Boxes

Custom rigid boxes — also called setup boxes — are the premium tier of packaging: thick chipboard wrapped in printed paper, holding a firm, structured shape that signals luxury the moment a customer lifts the lid. Unlike folding cartons, rigid boxes don't collapse, making them the choice for electronics, jewelry, cosmetics, spirits, and high-end retail. We manufacture in Connecticut with magnetic closures, lift-off lids, ribbon pulls, and custom foam or fitment inserts available. Runs start at 100 units with no setup or die charges and free contiguous-US shipping.

Why US brands choose us for custom rigid boxes

Custom Box Printing manufactures custom rigid boxes from our US production facility, with free standard shipping anywhere in the contiguous United States and a 7–10 business day turnaround. We've printed custom rigid boxes for solo founders launching their first product line, growing direct-to-consumer brands placing 5,000-unit runs, and established retail brands with 50,000+ unit production schedules — and we treat all three the same: no minimums, free design support, no setup or die-plate charges, and a 3D digital mockup before anything goes to press.

Every custom rigid boxes order includes free in-house dieline and artwork support — our US-based designers will polish your existing files, or build a custom dieline from scratch to fit your exact product dimensions. We send you a 3D mockup to confirm look and proportions before production. For color-critical work, request a physical sample for $50 — the full $50 is credited back to your production order the moment you proceed, so it's never a sunk cost.

Materials, print, and finish options

Rigid boxes are built on heavy grayboard or chipboard — typically 1.2 mm to 3 mm (around 28–98 pt) — wrapped in a printed litho sheet, then turned and edged by hand. The thick core won't flex or crush, supporting magnetic or lid-off closures and weighty inserts. Wrap stock takes soft-touch lamination, foil stamping, embossing, and spot UV beautifully; pair it with custom foam, EVA, or molded paper-pulp fitments to cradle the product.

Available finishes include:

• Lamination: Gloss, matte, soft-touch, or velvet finish for a premium hand-feel.
• Foil stamping: Gold, silver, copper, or custom foil colors for high-visibility brand marks.
• Embossing & debossing: Tactile raised or recessed surface effects on logo or key artwork.
• Spot UV: Selective gloss coating that creates contrast against matte areas.
• Eco-friendly options: Recycled kraft, FSC-certified stocks, water-based inks, recyclable rigid constructions.
• Compliance: FDA food-safe inks; certified child-resistant constructions for CBD/cannabis where required.

If you're not sure which combination will work best for your custom rigid boxes, mention it in your quote request — our team will recommend the right material, print spec, and finish based on your product, budget, and brand positioning.

How to order your custom rigid boxes

1. Request a quote — use the "Get Free Quote" button on this page, or call (855) 792-3890 (toll free). Tell us your box style, dimensions, quantity, material preferences, and any deadline.
2. We respond within 1 business day with pricing, lead times, and material recommendations. No pressure, no commitment.
3. Free design + 3D mockup — we build your dieline (or polish your existing artwork) and send you a 3D digital mockup to approve.
4. Optional physical sample — order a $50 sample to hold the box in hand. The full $50 is credited to your production order.
5. Production & free US shipping — once you approve, we print and ship in 7–10 business days, free anywhere in the United States.