Rigid boxes explained: two-piece, shoulder, book and drawer
By the Packaging Workshop team · Updated · 6 min read
Rigid boxes, also called set-up boxes, are built from thick greyboard wrapped in printed paper. They do not fold flat, they feel solid in the hand, and they are the usual choice for luxury gifts, jewellery and product launches.
How they are made
Greyboard, usually 1.5 to 3 mm thick, is cut and formed into trays. A printed or coloured paper wrap is glued over the board and turned in over the edges, about 15 mm, so no grey board shows. Corners are reinforced with tape before wrapping.
The main styles
Most rigid boxes are one of these:
- Two-piece: a base and a lift-off lid.
- Shoulder and neck: a base, an inner collar and a lid, with a visible band between.
- Book (magnetic closure): a tray fixed into a cover that opens like a book.
- Foldable magnetic: a book-style box that ships flat and is set up by hand.
- Drawer: a tray that slides out of a sleeve.
- Hinged lid and clamshell: lid and base joined by the wrap.
Artwork for wraps
Wrap artwork includes the turn-in, so it is larger than the box faces. Keep text away from the edges, which fold over, and expect slight variation at corners because wrapping is partly manual. Foil, embossing and soft-touch lamination are common finishes.
Cost and lead time
Rigid boxes cost more per unit than folding cartons and take longer to make, typically several weeks. They also take more space to ship and store because they are made up. A foldable magnetic box reduces freight cost while keeping the rigid feel.
Common questions
Are rigid boxes recyclable?
The board and paper wraps are, though magnets, ribbons and laminations may need removing first.
What inside clearance should a rigid box have?
About 3 to 5 mm each way, because rigid walls do not flex.
Can I get a rigid box dieline from PW Studio?
You can open every rigid style in the studio at your size as a guide dieline, then request the production file for your board.