Luxury rigid boxes — set-up boxes made to size
Custom Rigid Boxes
Rigid boxes are built from thick greyboard wrapped in printed or speciality paper, and they arrive assembled. We make them to your product's internal dimensions in magnetic closure, lid and base, drawer, book-style, shoulder and neck and collapsible constructions, finished with foil blocking, embossing or soft-touch lamination and fitted with an insert that holds the product still. Send your dimensions and quantity for a quotation.
- Construction
- Greyboard with a printed paper wrap
- Board
- Typically 1.5–3 mm greyboard
- Styles
- Magnetic, lid and base, drawer, book, collapsible
- Minimum order
- 50 boxes
Overview
What a rigid box is, and why brands choose one
A rigid box is specified in three layers: the greyboard that gives it structure, the wrap that carries the print, and the insert that holds the product. Because each layer is chosen separately, the same outside size can be built as a light retail gift box or a heavy presentation box for a bottle of fragrance. We build to your internal dimensions, so the product decides the box rather than a stock size.
The board is cut, V-grooved or scored and glued into shape, then covered with a wrap paper that is turned in over every edge. The finished box keeps square corners, resists crushing in the hand and does not flex when the lid is lifted. That permanence is why rigid boxes are kept and reused long after the product has gone, which a folding carton rarely is.
Rigid boxes cost more per unit than folding cartons and take more space to store and deliver, because most styles arrive assembled. They earn that cost where the packaging is part of what is being bought: gift sets, fragrance, jewellery and watches, spirits, premium electronics and corporate gifts. Where the box does not need to feel permanent, a folding carton in a heavier board is usually the better buy, and we will say so.
Single-colour rigid boxes are a common and effective variation. Instead of full-colour artwork, the wrap is a solid Pantone print or a coloured speciality paper, and the logo is foil blocked or blind debossed. The result is restrained and consistent across a range, and it avoids the scuffing that dark full-colour prints can show on edges.
Structures
Rigid box styles
Every style is built to your product's dimensions. The style decides how the box opens, whether it arrives flat or assembled, and how much storage space it takes.
Box style
Magnetic closure boxes
A hinged lid held shut by magnets concealed under the wrap. The usual choice for cosmetic gift sets, electronics and corporate gifts.
Read the style guideBox style
Lid and base boxes
A two-piece box with a separate lid that lifts off the base. Suits apparel, stationery, gift sets and shallow presentation boxes.
Read the style guideBox style
Drawer boxes
A tray that slides out of a wrapped sleeve, often with a ribbon pull. Popular for jewellery, chocolates and small accessories.
Read the style guideBox style
Book-style boxes
Opens like a hardback cover along a spine, usually with a magnetic front flap. Used for kits, watches and multi-part products.
Read the style guideBox style
Shoulder and neck boxes
A raised inner neck shows between lid and base when the box is closed. A traditional construction for fragrance and spirits.
Read the style guideBox style
Collapsible rigid boxes
The magnetic look, delivered flat and folded up by hand. Reduces storage and delivery volume on larger runs.
Read the style guideBox style
Sleeve and slipcase boxes
A wrapped slipcase or printed sleeve over a rigid tray or book-style box, for a layered opening.
Read the style guide
Sizing
Sizing a rigid box
Rigid boxes are sized from the inside out. Give us the length, width and height of the product, or of the product and its insert together, and we add the clearance a lid needs to lift cleanly or a tray needs to slide. The outside dimensions follow from the greyboard thickness and the wrap, which is why two boxes with the same internal size can measure differently outside.
A box that is too loose relies on the insert to stop movement; one that is too tight scuffs the wrap every time it is opened. Measure the product at its widest points in millimetres, including caps, pumps and closures, and tell us whether it sits upright or lies flat. If you already have a box whose fit you like, send its measurements as well.
For collapsible styles, think about both states: the flat box has to suit your storage, and the assembled box has to fit inside any courier outer. We confirm internal and external dimensions on the dieline before any board is cut.
Materials & finishing
Greyboard, wraps and linings
Greyboard thickness is set by the box size and the weight of the contents; the wrap is chosen for the print and the feel. The figures below are typical ranges that vary by mill and supplier, and we confirm the exact board on your quotation.
| Specification | Typical range | Notes |
|---|---|---|
| Greyboard (chipboard) | Typically 1.5–3 mm | Dense recycled board that gives the box its structure. Around 1.5 mm for small, light boxes, 2–2.5 mm for most gift and presentation boxes, and up to 3 mm for large or heavy contents. |
| Printed wrap paper | Typically 120–157 GSM coated art paper | Takes full-colour CMYK or Pantone print and is laminated before wrapping, so corners and edges resist scuffing in handling. |
| Speciality wrap papers | Textured, linen, coloured or metallic | Used where the finish is foil blocking or debossing alone, or where the paper's texture is part of the brand. Usually unprinted or lightly printed. |
| Inner lining paper | Printed or plain | Covers the inside of the lid and base. It can carry a different colour, a pattern or a short message from the outside. |
Finishes
- Matt lamination
- Gloss lamination
- Soft-touch lamination
- Foil blocking (hot foil stamping)
- Embossing and debossing
- Spot UV
- Die-cut windows
Options
Options you can specify
Printing
- Full-colour CMYK
- Pantone spot colours
- Single-colour wrap with a foil or blind-debossed logo
- Printed inner lid and tray
- Unprinted speciality paper
Constructions
- Tray, tray with sleeve and partial cover
- Neck boxes: straight, angled, hinged, or with a die-cut insert
- Clamshell boxes and three-sided hinged covers
- Flip-top boxes and book-style boxes
- Slipcases: plain, with thumb cuts, with a divider or with a flip top
- Slash cases and slip-and-slash sets
Closures and components
- Concealed magnets
- Ribbon pulls, ribbon ties and custom printed ribbon
- Thumb cut-outs
- Hinged lids
- Slipcases and sleeves
- Carry handles in rope, fabric or wrapped board
- Buttons, press studs and cord-and-bead closures
Wraps and speciality builds
- Textured and coloured fine papers
- Uncoated and recycled wraps
- Leatherette and cloth-effect wraps
- Leather and wooden presentation boxes
- Printed inner wraps and contrast linings
Inserts
- EVA or polyethylene foam cut to shape
- Card and greyboard cradles
- Wrapped greyboard trays
- Corrugated platforms for heavier items
Finishing
- Foil blocking in gold, silver, copper or coloured foils
- Cold foil printing, where the foil follows the artwork
- Blind, registered and combination embossing and debossing
- Spot UV on a matt or soft-touch surface
- Soft-touch lamination, or soft touch coating without a film
- Aqueous, UV and anti-scratch coatings
- Die-cut windows with a clear patch
Applications
Where rigid boxes are used
Fragrance and cosmetic gift sets
Magnetic or shoulder and neck boxes with a soft-touch wrap and an insert cut to the bottle or set, often matched to the brand's folding cartons.
Jewellery and watches
Drawer, book-style or lid and base boxes with a lined insert. The boxes are small, so a lighter greyboard is normally enough.
Spirits and wine
Heavier greyboard, a bottle-shaped insert and a lid that lifts cleanly against the weight of the bottle.
Electronics
Lid and base boxes with a fitted foam or card insert and a separate compartment for cables and accessories.
Corporate gifting
Collapsible magnetic boxes stored flat before a campaign, with a printed inner lid and a card insert for the branded items.
Health, wellness and pharmacy gift sets
Presentation boxes for premium supplement, skincare and wellness sets, where the box signals the top of the range.
Apparel and accessories
Shallow lid and base boxes with tissue and a ribbon pull for scarves, ties, small leather goods and knitwear.
Compare
Rigid box or folding carton?
| Feature | Rigid box | Folding carton |
|---|---|---|
| Construction | Greyboard, typically 1.5–3 mm, with a paper wrap | A single sheet of folding boxboard or SBS |
| How it arrives | Assembled (collapsible styles arrive flat) | Flat, glued at the side seam |
| Feel in the hand | Solid, heavy and square-edged | Light and flexible |
| Unit cost | Higher: more material and hand assembly | Lower, especially at larger quantities |
| Storage and delivery volume | High, unless a collapsible style is chosen | Low |
| Typical use | Gift sets, fragrance, jewellery, corporate gifts | Everyday retail units, cosmetics, food |
How to choose
How to choose your rigid box
Start with how it opens
Decide the opening moment first. A magnetic lid gives a one-handed reveal, a lid and base gives a lift-off reveal, and a drawer slides the product towards the customer. The style you choose also sets the delivery volume and the unit cost.
Match the board to the weight
Tell us the product weight rather than picking a board thickness. A heavy bottle in thin board will bow; a light jewellery piece in 3 mm board adds cost without adding anything the customer notices.
Decide early if you need it flat
If storage or delivery volume matters, choose a collapsible style at the start. Other rigid styles are glued up and cannot be flattened later.
Plan the insert with the box
The insert sets the product height, the view when the lid opens and how well the product survives handling. Specify it together with the box, not afterwards.
Let one finish lead
Soft-touch lamination with a single foil-blocked logo often reads more premium than several finishes competing on the same lid. Each finish is a separate process, so fewer, better choices also keep the specification simpler.
Plan the outer if it ships
A rigid box is presentation packaging, not a transit box. If it travels by courier or post, plan a mailer box or corrugated outer around it so the wrap arrives unmarked.
In detail
What goes into a well-made rigid box
Clean wrap turn-ins
The wrap should be turned in evenly over each edge and pressed flat inside the lid and base. Wrinkles, lifting corners and visible board edges are the first things a customer notices, so we check them on every run.
Finishes applied before wrapping
Foil blocking, embossing and spot UV are applied to the flat wrap sheet before it goes onto the board. That is how the finish registers precisely and stays crisp on the finished box.
Hand assembly and timing
Rigid boxes are wrapped by hand and machine, and magnets, ribbons and inserts are fitted by hand. That is the main reason rigid jobs take longer than folding cartons. Tell us your required delivery date and our team will confirm whether the timing is achievable.
Printed insides
The inner lid and tray can carry a separate print, a message or a change of colour. It is seen only when the box is opened, which is exactly why brands specify it.
Finished work
Rigid Boxes we have made
Magnetic closure boxes · Greyboard 
Lid and base boxes 
Magnetic closure boxes · Foil blocking 
Lid and base boxes · Greyboard 
Hexagonal rigid box with carry handle 
Drawer boxes 
Lid and base boxes · Foil blocking Collapsible rigid boxes
Rigid Boxes 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 the difference between a rigid box and a folding carton?
A rigid box is made from thick greyboard wrapped in printed paper and usually arrives assembled; a folding carton is a single sheet of printed board that is delivered flat and folded up at packing. Rigid boxes are stiffer and cost more per unit but present a product far better. Many brands use a rigid box for gift sets and a folding carton for the everyday retail unit.
Can rigid boxes be delivered flat?
Yes, if you choose a collapsible construction. Collapsible magnetic boxes fold flat and are put together by hand in a few moves, which saves storage and delivery volume on larger orders. Lid and base, drawer, book-style and shoulder and neck boxes are supplied assembled.
How thick is the greyboard in a rigid box?
Typically 1.5–3 mm, depending on the box size and the weight it has to carry. Small jewellery boxes sit at the lighter end; boxes for bottles, electronics or large sets use heavier board. Tell us the product and its weight and we specify the board on your quotation.
What is the minimum order for rigid boxes?
The minimum order is 50 boxes. Unit cost falls as the quantity rises because setup and make-ready are spread across the run, so if you are deciding, ask for two or three quantities on your quote request and compare.
How long does a rigid box order take?
It depends on the style, the finishes and the quantity. Rigid boxes involve proofing, wrapping, hand assembly and fitting of magnets, ribbons and inserts, so they take longer than folding cartons. Tell us your required delivery date and our team will confirm whether the timing is achievable.
Can you print inside a rigid box?
Yes. The inner lid and the tray can be lined with printed paper in a different colour or design from the outside. It is a small addition that changes the opening moment noticeably.
Do rigid boxes need an insert?
Most do. A rigid box is usually larger than the product, and without an insert the product moves when the box is tilted or turned over. EVA foam, card cradles and wrapped greyboard trays are the common choices. Send the product dimensions and we will propose one.
Can I see a sample before production?
You approve a digital proof showing your artwork on the dieline before anything is produced. Ask about sample options when you request your quotation.
Can a rigid box be posted on its own?
It can, but the wrap and corners are likely to mark in a courier or postal network. For anything posted to a customer, we recommend a printed mailer box or a corrugated outer sized around the rigid box.
Are rigid boxes recyclable?
Greyboard and paper wraps are paper-based. Lamination films, foam inserts, magnets and ribbons are separate materials that affect how easily a box can be recycled. If recyclability matters to you, raise it at specification stage and we can suggest card inserts, uncoated papers or fewer components.
Ready to specify your packaging?
Our team replies during business hours, 10:00–18:00 UK time.