Die-cut boxes are shaped packaging. Instead of a standard rectangle, the box is cut to a custom outline that matches your product or brand aesthetic. At Teal Packaging, custom die-cut boxes start at $1.35/unit with a minimum order of 100 pieces.
What Makes Die-Cut Different
Every box starts as a flat sheet. Standard boxes use generic cutting templates (tuck-end, mailer, etc.). Die-cut boxes use a custom steel rule die, machined to your exact specifications. That die stamps out your unique box shape from the flat sheet in one press.
The die itself costs $150 to $500 depending on complexity, but it is a one-time cost. Once your die exists, every reorder uses the same tooling at no additional charge.
Common Die-Cut Box Styles
- Hexagonal boxes: Six-sided shapes popular for candles, honey jars, and premium gift sets. Stands out on shelves because nothing else around it is hexagonal.
- Pillow boxes: Curved top and bottom edges that pinch together. Used for jewelry, small accessories, and wedding favors. No glue needed, the shape holds by friction.
- Heart-shaped boxes: Seasonal favorite for Valentine chocolates, but also used year-round by jewelry and cosmetics brands.
- Triangular/pyramid boxes: Unusual shapes that work for premium chocolates, perfume samples, and promotional packaging.
- Custom product silhouettes: Box shaped like the product inside (guitar pick box, shoe-shaped box, bottle-contoured box). Maximum shelf impact.
Materials and Specs
Die-cut boxes work with most packaging substrates:
- SBS (Solid Bleached Sulfate): 14pt to 24pt. Best for intricate die-cuts because the board is dense and cuts cleanly. Smooth white surface.
- CCNB (Clay Coated News Back): 18pt to 24pt. More economical than SBS. Grey interior, white exterior. Good for retail boxes where only the outside matters.
- Corrugated: E-flute only for die-cut shapes. Thicker flutes (B, C) do not hold complex curves well.
- Rigid board: 50pt+ chipboard wrapped in printed paper. For ultra-premium die-cut boxes like luxury perfume or jewelry packaging.
Pricing
- 100-499 units: $2.10 to $4.50 per box (includes die creation)
- 500-999 units: $1.55 to $3.20 per box
- 1,000-2,999 units: $1.10 to $2.40 per box
- 3,000+ units: $0.78 to $1.85 per box
First orders include die creation cost ($150-$500). Reorders skip that fee entirely, dropping per-unit cost by $0.15 to $0.50 depending on volume.
Design Considerations
Complex die-cuts require wider margins around fold lines (minimum 4mm vs the standard 3mm). Avoid sharp interior angles under 60 degrees because the board tends to crack or tear at acute bends. Round your interior corners with at least a 2mm radius.
If your box has a window cutout combined with a custom shape, plan for the window film to be applied as a separate step after die-cutting. This adds about $0.08 to $0.15 per unit.
Get Started
Send us your concept (sketch, AI file, or even a napkin drawing) and our design team will build a 3D structural mockup free of charge. MOQ is 100 boxes. Production takes 15-20 business days. Request your free quote here.
Die-Cut Box Design Guidelines
Complex shapes require thoughtful design to manufacture reliably:
Minimum feature size: Cut lines should be at least 3mm apart. Tighter than that risks tear-through during cutting.
Corner radius: Sharp interior corners (under 60 degrees) risk cracking. Round corners to at least 2mm.
Fold lines: Score lines need at least 4mm clearance from cut lines. This prevents the board from weakening at the fold.
Material thickness: Thicker materials (24pt+) can not achieve tight bends. If your design has tight curves, use thinner board (14-18pt).
Die-Cut Box Prototyping
We recommend a prototype before full production:
- PDF proof: Digital proof showing the flat layout. $0.
- White model: Unprinted sample from your dieline. $25-$50.
- Full color prototype: Production-quality sample with your print. $50-$150.
Order Die-Cut Boxes
MOQ 100 units. Production 18-22 business days. Get a quote.