Custom Clamshell Packaging is a hinged die-cut box where the lid and base are cut as one piece that folds shut, made from corrugated board and printed in full color for brands that want a quick open-and-close pack. It suits products that get handled and reshelved often.
The single-piece hinge means no separate lid to lose and a closure that opens and snaps back without tape, which keeps the contents secure between uses. The corrugated structure protects the product while the printed surface carries your branding straight through to the buyer. Brands use clamshell boxes for kits, gift sets, and items that customers re-open, where a tidy reclose matters as much as the first impression.
Materials & Specifications
- Material: Corrugated board (E-flute light, B or C-flute heavier)
- Construction: One-piece die-cut clamshell with a hinged lid and tuck closure, no tape
- Printing: Full-color CMYK, print inside and outside
- Finishing: Matte or gloss lamination, custom inserts to seat the product
- Sustainability: FSC-certified paper available
Best Used For
- Gift sets and product kits that customers re-open
- Retail items that need a clean reclose on the shelf
- Sampler and bundle packs with a fitted insert
Printing & Finishing
Print full-color CMYK across the outer shell and inside the lid, then add matte or gloss lamination for a smoother finish. A custom insert seats the product so it stays put each time the clamshell is opened and closed.
Why Order from Teal
Teal manufactures clamshell packaging in the US with a 50-unit minimum, so you can test a kit format without overcommitting. You get free design help, free US shipping, full-color CMYK printing, and an FSC-certified paper option. Pick standard production at about 7 business days, or a rush service (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) when timing is tight.
FAQ
What's the minimum order quantity? The standard minimum is 50 units, with specialty rigid styles starting at 100.
How long is production? Standard production runs from about 7 business days, with a rush service available (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs).
Can I get a sample? Yes. A $50 sample kit is available and credited to your first order.
Request a free quote and we'll get back to you within 4 business hours.
Thermoformed Clamshell Tooling and Run Size
Clamshells are thermoformed, which means an aluminum tool defines the cavity and every later order reuses it. Material gauge governs how firmly the shell snaps shut; too thin and the hinge fatigues, too thick and the pack fights the shopper. RPET content is available and should be specified up front because it changes forming temperature.
| Shells per order | Gauge and tooling guidance |
|---|---|
| 50 | Prototype quantity to validate cavity fit and hinge. |
| 500 | First production pull from a single cavity tool. |
| 1,000 | Gauge adjustments made before the tool is multiplied. |
| 5,000 | Multi-cavity tooling shortens the forming cycle. |
| 10,000+ | Retail programs quoted from about $0.44 per unit at volume. |
Reserve about 7 business days once the tool exists and the job is in-house eligible; new tooling or specialty imported material can extend the timeline to about 12 weeks. Plan with the outer figure until tooling is proven. Free dieline and cavity drawings accompany the tooling stage.
Provide product dimensions, weight, hinge preference, material gauge, RPET content, and the annual volume you expect.
How to Order Custom Clamshell Packaging
Ordering custom clamshell packaging is simple:
- Submit a quote request with your dimensions, quantity, and design references
- Receive quote guidance within one business day
- Send your artwork or work with our design team (free dieline + 2 revision rounds)
- Approve the digital proof and production begins
- Standard production runs from about 7 business days after proof approval; complex or high-volume orders take longer
