Custom Kraft Die Cut Boxes for Precise, Branded Packaging
Custom kraft die cut boxes offer a level of precision and structural flexibility that standard folding cartons cannot match. By cutting kraft paperboard to an exact custom shape using a steel-rule die, manufacturers and brands can create boxes that hug the product, support complex locking mechanisms, and carry intricate design cutouts that elevate the unboxing experience. At Teal Packaging, we produce die-cut kraft packaging starting at 50 units with a two-week lead time, free design support, and free shipping to the US, Canada, UK, and Australia. If your product does not fit a standard box shape, die-cutting is the answer.
Die-cut kraft packaging is used across retail, food, cosmetics, and e-commerce because the kraft material holds a score line cleanly and assembles with consistent results even at scale. The natural brown surface pairs beautifully with both minimal branding and bold full-color designs, giving brands across every sector a versatile packaging foundation.
Materials and Board Weights
The performance of a die-cut box depends heavily on the board weight and grain direction relative to the cut lines. Our custom kraft die cut packaging is produced using FSC-certified kraft paperboard in the following weights:
- 250 gsm: Lightweight, clean-cutting, suitable for shallow trays, sleeve packaging, and simple auto-lock bottom boxes for lighter products.
- 300 gsm: The standard weight for most die-cut box applications. Provides reliable fold strength, good print surface, and excellent structural integrity for retail and gifting contexts.
- 350 gsm: Premium weight ideal for rigid-feel die-cut packaging, luxury product boxes, and configurations that require a heavier base weight to maintain shape under product weight.
- 400 gsm: Maximum paperboard weight, used for high-end jewelry boxes, electronics accessories, and packaging applications where thickness contributes to perceived product value.
All boards are available with soy-based ink printing, which delivers sharp, accurate color reproduction on kraft's warm natural surface. Finishing options include matte lamination, gloss lamination, soft-touch coating, spot UV, embossing, and foil stamping.
Customization Options
The defining feature of die cut kraft boxes is the ability to create any outline shape, interior cavity, or cutout feature your design requires. Our customization options include:
- Custom die shapes: Any external box shape, from straight-edged rectangles to curved-edge trays and complex structural forms.
- Window cutouts: Precisely shaped openings for product visibility, covered with clear PET film or left open for airflow on breathable products.
- Locking mechanisms: Auto-lock bottoms, crash-lock bases, tuck locks, and interlocking flaps all rely on precise die-cut scores and cuts for reliable function.
- Internal structure: Die-cut inserts, display stands, and compartmentalized trays formed from the same kraft stock.
- Print coverage: Full exterior CMYK printing, interior printing, and spot color options. Pantone matching available.
Our free design support team manages dieline development as part of every order. If you have a structural idea but no technical dieline, we will build it. If you have an existing dieline, we will review it and flag any production concerns before cutting a steel-rule die.
For brands that want a structured rigid box without die-cut complexity, our custom rigid boxes offer a set-up box format using premium board construction.
Standard and Custom Sizes
Because die-cut boxes are built to a custom specification, dimensions are determined by your product. Common reference sizes we produce in die-cut kraft formats include (length x width x depth in inches): For related packaging needs, explore our shipping mailers.
- 3 x 3 x 1 in - Small tray, product sample, accessory packaging
- 4 x 3 x 2 in - Compact retail product box, cosmetic packaging
- 5 x 4 x 2 in - Standard single-product retail box
- 6 x 4 x 2.5 in - Mid-size retail, food, or tech accessory box
- 8 x 5 x 3 in - Gift-ready die-cut box with lid tuck or magnetic closure option
- 10 x 6 x 4 in - Multi-item packaging, subscription product kits
- 12 x 8 x 4 in - Large retail or e-commerce product packaging
Fully custom dimensions are the norm for die-cut orders. Submit your interior product dimensions during the quote process and our team will develop a matched dieline. Brands with display requirements should also explore our custom display boxes for retail-ready kraft configurations.
Sustainability
Die-cut kraft packaging is one of the most sustainable structural packaging formats available. Our approach to sustainability covers the full material and production lifecycle:
- FSC-certified kraft board: Every board we use is sourced from certified sustainable forests through verified supply chains.
- Soy-based inks: Lower environmental impact than petroleum inks, with better recyclability and reduced volatile emissions during printing.
- Efficient material use: Die-cutting is engineered to minimize trim waste through nesting optimization. Less waste per box run means a lower material footprint.
- Fully recyclable: Kraft paperboard is accepted in curbside recycling programs across our shipping markets. Uncoated versions are also suitable for industrial composting.
For brands assembling a cohesive eco-friendly product line, our kraft boxes collection covers a broad range of kraft packaging styles to create a consistent sustainable identity across your SKUs.
How to Order
Ordering custom kraft die cut boxes from Teal Packaging involves a few additional dieline steps compared to standard cartons, but our team manages the complexity for you:
- Request a quote: Provide your product dimensions, desired board weight, quantity, and any known structural requirements. We will respond with pricing and a timeline within one business day.
- Dieline development: Our design team develops a structural dieline matched to your product. You review and approve the structure before artwork is applied.
- Artwork application: Once the structure is confirmed, artwork is applied to the dieline. A full-color digital proof is sent for your approval.
- Die production and manufacturing: Once your proof is approved, a custom steel-rule die is produced and manufacturing begins. Total lead time is two weeks from proof approval.
- Free shipping: Finished boxes ship free to the US, Canada, UK, and Australia.
Our minimum order of 50 units applies to die-cut orders, though some highly complex structural forms may have a higher minimum due to die setup costs. Our team will confirm this during the quoting process. For related packaging needs, explore our retail boxes.