Materials · Rigid board
Greyboard (chipboard) for rigid boxes
Greyboard is the thick, dense board that gives a rigid box its structure. It is never printed directly: it is wrapped in printed or speciality paper, so the board does the structural work and the wrap carries the look. Most rigid boxes use greyboard between 1.5 mm and 3 mm, chosen by the size and weight of what goes inside. This page explains thickness, density, grades and wrapping so you can specify it with confidence.
Overview
What greyboard is and how it becomes a box
Greyboard is a solid, unlined board pressed from layers of paper fibre, usually recycled, which gives it the grey to grey-brown colour that names it. Chipboard is the North American name for the same material; in the UK that word usually means wood particleboard, so greyboard is the clearer term when you talk to a supplier. Very dense, hard grades are sometimes sold as millboard.
Unlike folding boxboard, greyboard is not made to crease and fold. It is cut into flat panels, the panels are joined at the corners, and the whole shell is covered with a wrap: a printed and laminated paper, or a speciality paper, glued over the outside and turned in over the edges. A paper liner then covers the inside. That is why rigid boxes arrive already assembled and hold their shape for years of reuse.
Thickness is the main decision. Most rigid boxes use board between 1.5 mm and 3 mm. 2 mm is the everyday choice for gift and presentation boxes, 1.5 mm suits small, light boxes, and 2.5–3 mm is used for large lids and heavy contents such as bottles. Thicker board is stiffer and feels more substantial in the hand, but it is heavier, bulkier and needs more careful corner work.
Density matters as much as thickness. Greyboard usually sits somewhere around 600–800 kg per cubic metre, depending on the mill, so a 2 mm sheet typically weighs about 1,200–1,600 gsm. A denser board of the same thickness is harder, resists dents better and gives crisper edges under the wrap. When you compare quotations, check that both the thickness and the grade or weight are stated, not just one of them.
How the corners are made changes the finish. Panels can be joined with corner stays (strips of tape) before wrapping, or V-grooved, where a V-shaped channel is cut part way through the board so it folds into a sharp, square edge. The wrap, commonly a 120–157 gsm paper when printed and laminated, must be strong enough to turn over the edges and corners cleanly without splitting.
Specification
Typical specification
| Specification | Typical range | Notes |
|---|---|---|
| 1.5 mm greyboard | 1.5 mm (about 900–1,200 gsm) | Small, light boxes such as jewellery, cards, accessories and inner trays. Stiff enough for a neat box, but large panels can flex. |
| 2 mm greyboard | 2 mm (about 1,200–1,600 gsm) | The standard for gift, cosmetics and presentation boxes: a good balance of stiffness, weight and crisp edges. |
| 2.5 mm greyboard | 2.5 mm (about 1,500–2,000 gsm) | Larger boxes, book-style and magnetic lids that must stay flat, and moderately heavy contents. |
| 3 mm greyboard | 3 mm (about 1,800–2,400 gsm) | Heavy or high-value contents such as bottles and hampers, and large lids that would otherwise bow. |
| Wrap paper | Commonly 120–157 gsm | Printed and laminated art paper, kraft paper or a speciality paper glued over the board and turned in over the edges. |
| Liner paper | — | Covers the inside of the shell and hides the turn-ins; plain, coloured or printed to match the outside. |
Best for
Where it works best
Gift and presentation boxes
Boxes that are kept and reused, where the permanence of greyboard is part of the value.
Jewellery
1.5–2 mm board gives a small, precise box with a firm, well-fitting lid.
Cosmetics and fragrance
Shoulder and neck or magnetic boxes that feel weighty and composed on the counter.
Drinks and spirits
2.5–3 mm board with a fitted insert carries a bottle securely in the hand.
Corporate gifting and launch kits
Book-style and drawer boxes that present several items together in one keepsake.
Electronics and accessories
A rigid shell with a fitted insert stays square on the shelf and when opened.
Limitations
Where it falls short
- Rigid boxes ship assembled, so they take far more space in transit and storage than flat-packed cartons; collapsible rigid boxes reduce this.
- Greyboard cannot be creased and folded like carton board, so it only suits set-up constructions.
- It absorbs moisture. Damp storage or unbalanced gluing can warp panels, which is why the wrap and liner are balanced on both faces.
- It is heavier than folding boxboard or corrugated for the same box size, which adds to shipping weight.
- A rigid box is a presentation box, not a transit carton; for courier delivery it usually needs an outer shipper.
- The raw board is not a printing surface; all branding goes on the wrap, so the wrap choice decides the look.
Pairs with
Works well with
Material
Speciality papers
Textured, metallic and leatherette-style wraps give greyboard its finish without heavy print.
Read moreFinish
Lamination
Printed wraps are laminated to protect the print where it turns over edges and corners.
Read moreFinish
Foil blocking
A foil logo on the wrapped lid is the classic rigid-box treatment.
Read moreFinish
Embossing and debossing
Dense greyboard holds a deboss well, giving a crisp recessed logo.
Read moreBox style
Magnetic closure boxes
The most requested greyboard construction, with magnets set into the board.
Read moreProduct
Rigid boxes
Our whole rigid box range is built on greyboard.
Read more
Compare
Which greyboard thickness?
| Feature | 1.5 mm | 2 mm | 2.5–3 mm |
|---|---|---|---|
| Feel in the hand | Light and neat | Solid and substantial | Heavy and very firm |
| Typical box size | Small: jewellery, cards, accessories | Small to medium: most gift and cosmetic boxes | Large lids, hampers, bottle boxes |
| Contents weight | Light | Light to moderate | Moderate to heavy |
| Risk of panels bowing | Higher on large panels | Low at typical sizes | Lowest |
| Shipping weight | Lowest | Moderate | Highest |
How to choose
How to choose greyboard for your box
Start with size and weight
Tell us the product dimensions and weight. Larger panels and heavier contents need thicker board, so the lid stays flat and the base does not sag when the box is lifted.
Decide how the box will travel
If the rigid box goes through a courier network, plan an outer shipper, or consider a collapsible rigid box that ships flat and is set up at packing.
Choose the wrap with the finish
The wrap carries every visual decision. Printed and laminated wraps suit full artwork; speciality papers suit foil blocking and debossing with little or no print.
Plan the insert at the same time
Most rigid boxes hold the product in a fitted insert. The insert changes the internal space, so specify the box and the insert together from the product's own measurements.
Ask for the board in writing
Compare quotations on board thickness, grade or weight, wrap paper and lamination, not on the word rigid alone. Your quotation confirms the exact board we will use.
Finished work
Greyboard on finished packaging
Magnetic closure boxes · Greyboard 
Lid and base boxes · Greyboard
Greyboard questions
Questions buyers ask
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat is greyboard?
Greyboard is a thick, stiff, unlined board, usually made from recycled paper fibre, used as the structural core of rigid boxes. It is typically 1.5–3 mm thick. It is cut into panels, wrapped in printed or speciality paper and lined inside, rather than printed directly.
Is greyboard the same as chipboard?
Yes, in packaging. Chipboard is the American name for the same board. In the UK, chipboard usually means wood particleboard used in furniture, so greyboard is the clearer word to use when you specify rigid boxes.
What thickness of greyboard do rigid boxes use?
Most rigid boxes use 1.5–3 mm. 2 mm is the everyday choice for gift and cosmetic boxes, 1.5 mm suits small, light boxes such as jewellery, and 2.5–3 mm is used for large lids and heavy contents such as bottles.
How much does greyboard weigh?
It depends on density, which varies by mill. A typical range is around 600–800 kg per cubic metre, so 2 mm greyboard usually weighs about 1,200–1,600 gsm. A denser board of the same thickness feels harder and resists dents better.
Can greyboard be printed directly?
Not for finished packaging. Greyboard is a structural board with a rough, grey surface. All printing goes on the wrap paper, which is then glued over the board. Lined greyboard with a white or black face exists for simple uses, but premium boxes are wrapped.
Can a rigid box ship flat?
A standard rigid box cannot, because the greyboard panels are fixed at the corners. A collapsible rigid box uses wrapped panels that fold flat and are set up at packing, often held by magnets, which saves a lot of space in transit and storage.
What is the difference between greyboard and folding boxboard?
Greyboard is thick, dense and wrapped; it is built into set-up boxes that arrive assembled. Folding boxboard is much thinner, printed directly, creased and folded, and ships flat. Greyboard gives permanence; folding boxboard gives print quality at a lower weight.
Is greyboard recyclable?
Greyboard itself is a paper-based board. A finished rigid box also contains glue, a wrap that may be laminated, and sometimes magnets or ribbon, which affect how it is sorted. If recyclability matters to your brief, tell us at specification stage so the wrap and components are chosen with it in mind.
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