Custom Die Cut Boxes & Die Cut Packaging
A die is essentially a shaped blade mounted in wood that stamps your outline out of a flat sheet. Every carton you have ever opened started that way. What makes it interesting is that the die can be any shape at all, which means your box is not limited to a rectangle. We produce a lot of die cut packaging at ZEE Packaging and the tooling is where the possibilities open up.
The Die Decides The Shape
A die cut box can be any outline you draw.
- A steel rule blade is bent to your dieline and mounted
- It cuts and creases the sheet in one pass
- Windows, handles and slots are cut at the same time
- The shape is not limited to standard rectangular formats
- Once made, the die repeats identically on every run
- Precision is far higher than any manual cutting
Most brands ordering a die cut box do so because a stock shape did not suit their product.
Worth understanding before you budget.
- The die is made once and charged once
- It is stored and reused on every subsequent order
- Complex shapes cost more to tool than simple ones
- Sharp internal angles are harder to cut cleanly
- Nesting efficiency affects how much board is wasted
- We quote tooling separately so you can weigh it up
- Standard folding carton the everyday die cut box
- Shaped outline following a logo or a product form
- Window carton a die cut aperture in a panel
- Handle box a punched or cut carry hole
- Mailer with an insert cut in a single die
- Interlocking tab structures assembling without glue
Sizes We Print Regular
Every die cut box is built to your product, though these run often:
- 6" x 4" x 2" for small items
- 8" x 6" x 3" for a standard order
- 3" x 3" x 4" for a candle or jar
- 10" x 8" x 4" for a mailer
- 12" x 9" x 3" for apparel
- Any custom outline you supply
Send us your product and we draw the dieline around it. Working from a stock size rarely fits properly.
Board And Cutting
- SBS C1S for retail folding cartons
- Kraft board for a natural or artisan position
- Corrugated E and B flute for mailers and shippers
- Rigid greyboard for built formats
- Crease depth set to suit the caliper
- Precision cutting on windows, slots and tabs
Crease depth is the detail that matters most. Too shallow and the fold resists, too deep and the board splits, so we set it against your caliper specifically.
Materials Worth Choosing
- Recycled board across most grades we run
- FSC certified stock, certificate available on request
- Soy based ink through the whole run
- Efficient dieline nesting, so less board is trimmed away
- Interlocking tabs, removing the need for glue entirely
- Right sizing so no material is wasted per carton
Nesting efficiency is a real environmental factor. A well laid out die wastes considerably less board across a large run.
What Ordering Involves Here
- 100 unit minimum, so a small brand can order properly
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- Physical sample on request to check the cut and fold
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
How much does a die-cut box cost?
Rough estimate is $0.18 to $0.60 per unit for a folding carton, $0.35 to $0.90 for corrugated and $1.80 to $4.20 for rigid at moderate quantity. Tooling is a small one off. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
How much is the tooling?
Less than most people expect, and charged once rather than per order. Complex shapes cost more than simple outlines.
Do you store the die?
We do, so reorders skip tooling entirely and go straight into production.
Can you cut any shape?
Almost. Very sharp internal angles are difficult, and we would flag anything that will not cut cleanly.
Can we supply our own dieline?
Yes, and plenty of studios do. We check it against our tooling before quoting to avoid surprises.
Why does my crease crack?
Crease depth wrong for the board caliper, or heavy ink on the fold. Both are set correctly at tooling stage.
Can windows be cut too?
Yes, in the same pass. Handles, slots and tabs all come from the same die.
How much does a die-cut box cost?
Rough estimate is $0.18 to $0.60 per unit for a folding carton, $0.35 to $0.90 for corrugated and $1.80 to $4.20 for rigid at moderate quantity. Tooling is a small one off. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
