
Varnish
A transparent finishing layer available in gloss, satin, or matte effects. It enhances the printed surface and adds an extra layer of visual appeal and light protection.
Different Shape Boxes are die-cut to your own outline instead of a standard rectangle, built for a product that doesn't fit one or a brand that wants to stand out on a shelf. Orders start from 100 units. Getting the outline right before production, from design input to a 3D mock-up, costs nothing extra.
Buyers land on this page for one of two entirely separate reasons, and the reason behind the order is what actually determines how the build should be judged.
Sometimes the product itself isn’t rectangular. A curved, tapered or irregular item can sit awkwardly in a straight-sided box, wasting space around it or leaving it loose enough to shift in transit. Here, the shape is a functional answer to the product’s own form, not a styling choice. Other times, the product is perfectly ordinary, and the shape exists purely to make the box stand out on a shelf or in an unboxing moment, a marketing decision rather than a structural necessity. Both are genuine reasons to order a non-rectangular box, but they lead to different priorities. A functional shape is judged on how well it fits and supports the product. A decorative shape is judged on how well it reads as a shape from a distance. Either way, a die-cut outline is only worth commissioning custom-fit tooling for once the reason behind it is clear.
A box with straight sides and right angles stacks and nests predictably, because every unit sits flush against the next one in a pallet or on a shelf. That’s general packaging mechanics, not anything specific to this range. A custom outline breaks that predictability. Curves, points and asymmetric edges leave gaps a rectangular box wouldn’t, and a shape chosen purely for shelf standout can end up costing real storage and handling efficiency in the warehouse before it ever reaches that shelf. This isn’t a reason to avoid a custom shape, since plenty of products genuinely need one. It’s a real cost worth weighing against the visual benefit, and it applies equally to a functional shape and a purely decorative one.
Every non-standard outline starts from a die tool shaped to what’s actually being packed or shown, not from a fixed catalogue of standard forms. Printing runs across whatever surface the finished shape has, offset, digital or screen. Pantone references and CMYK values can be used to manage colour consistency, subject to normal variation caused by the chosen board, ink, coating and production method. Orders start from 100 units. Design support is free. A digital 3D mock-up is free. There are no setup fees. Standard production takes 6 to 8 business days after approval. UK delivery is free.
A shape that’s already fixed and named, rather than something to work out from scratch, is often already a product in its own right, Dog Bone Shaped Boxes among them. Committing to cardboard specifically rather than leaving the material open sits under Custom Shaped Cardboard Boxes instead. For the standard rectangular format this page exists to differ from, Custom Product Boxes covers the rest of the range.
| Box Style | All Custom Packaging |
| Dimension | All Custom Sizes & Shapes |
| Quantities | 100-unit minimum order |
| Paper Stock | Kraft, corrugated, rigid board, cardstock |
| Printing | CMYK, Pantone, digital and offset |
| Finishing | Gloss, matte, spot UV, embossing, foiling |
| Shipping | Free delivery options |
Choose from premium coating, board, printing and finishing options for your insert boxes.

A transparent finishing layer available in gloss, satin, or matte effects. It enhances the printed surface and adds an extra layer of visual appeal and light protection.

A UV-cured coating applied to specific areas of the design to create gloss or matte contrast and draw attention to important details.

A smooth, velvety coating that creates a soft tactile feel and gives packaging a refined luxury look. It improves the unboxing experience and supports a high-end product presentation.

A soft, smooth lamination with a refined satin-like finish. It gives packaging a premium feel while keeping the surface elegant, subtle, and easy to handle.

A high-gloss UV coating applied only to selected design areas to create sharp contrast, highlight logos, and add a premium visual effect without coating the whole surface.

A clear, fast-drying water-based coating that adds a smooth protective layer while maintaining a clean and professional surface finish. It is a practical choice for everyday printed packaging.

A durable protective film that helps reduce visible scratches, scuffs, fingerprints, and daily handling marks. It keeps packaging looking clean, polished, and premium for longer.

A bleached kraft paperboard made from a mix of virgin and recycled pulp, offering a clean white surface for crisp and polished packaging designs.

A natural kraft paperboard without coating, made from virgin and recycled pulp. It provides a raw, organic appearance with sturdy packaging strength.

A premium bleached paperboard coated on both sides, designed for excellent print quality, die-cutting, and professional packaging results.

A high-quality bleached paperboard coated on one side. It provides a clean printable face with a premium packaging feel.

A smooth printable paper stock that supports high-resolution graphics, clean text, and rich color output for refined packaging presentation.

A natural kraft paperboard made from strong virgin and recycled pulp. It provides an organic, earthy look for sustainable and simple packaging.

A specialty paperboard with a laminated metallic surface available in gold, silver, and other premium finishes for luxury visual impact.

A specialty paperboard with a laminated holographic surface that creates a reflective, rainbow-like appearance for eye-catching product packaging.

A recycled duplex paperboard with a white printable surface. It is ideal for economical packaging that still requires clean graphics and brand presentation.

A kraft board with a smooth clay-coated white face for quality printing and a natural kraft reverse side for a strong, authentic appearance.

A kraft paperboard with a clay-coated printable top surface and a natural unbleached kraft back. It balances clean branding with a rustic natural look.

A duplex paperboard made with recycled pulp and a coated white printable surface. It delivers smooth print results for affordable carton packaging.

A black-dyed kraft board with a natural paper texture and excellent strength. It creates a bold, premium look for luxury and specialty packaging.

A packaging technique where a die-cut opening is covered with a transparent film, allowing the product inside to remain visible while staying protected.

An embossing technique where the raised design is precisely aligned with printed artwork to improve detail, texture, and overall presentation.

A finishing process in which heat and pressure transfer metallic foil to the surface, creating a premium, shiny, and luxurious effect.

A premium finishing method that combines embossing with foil stamping to create a raised design with metallic color and strong visual impact.

A decorative process that transfers foil onto selected areas of the surface using UV-curable adhesive, creating a bright metallic effect with sharp detail.

A technique that raises a design from the surface without ink or foil, giving packaging a clean, elegant, and textured appearance.

A finishing technique that presses a design into the material to create a recessed impression without using ink or foil. It adds subtle depth and a refined tactile effect.

A fast-curing printing process that uses ultraviolet light to dry ink instantly, delivering sharp detail, vibrant colors, and a premium finish.

A durable printing method that uses a mesh screen and stencil to apply ink to surfaces. It is ideal for bold colors and high-impact packaging designs.

A traditional high-quality printing process that transfers designs from plates to a rubber blanket before printing, making it ideal for large-volume production.

A modern printing method that does not require printing plates, making it cost-effective and efficient for short runs, sample production, and small-batch quantities.

Built with three corrugated layers between four linerboard sheets, providing heavy-duty strength for large or industrial packaging needs.

A standard corrugated structure with one fluted medium and two linerboards, providing dependable strength for everyday packaging.

A corrugated sheet with one flute layer between two liners, offering lightweight strength for protective packaging.

An ultra-thin flute grade designed for lightweight packaging, small retail boxes, and high-quality printed presentation.

A slim flute grade with a flatter surface, ideal for detailed printing, display packaging, and premium retail boxes.

Made with two layers of corrugated medium between linerboard sheets, offering added strength and durability for heavier products.

A versatile corrugated flute that offers balanced compression strength, cushioning, and printability for many packaging applications.

A thinner flute grade with a smooth surface, making it suitable for high-quality printing, precise die-cutting, and neat retail packaging.

A thick corrugated flute profile that provides excellent cushioning, compression strength, and stacking support for protective packaging.

A coated linerboard with an off-white surface, suitable for high-quality printing and a refined packaging appearance.

An unbleached kraft linerboard made from recycled paper pulp, offering a natural look with strong durability for eco-conscious packaging.

A coated semi-gloss linerboard with a smooth white surface, ideal for sharp printing, premium presentation, and retail-ready packaging.

A fully bleached corrugated board with a bright white surface, designed to produce clean, vibrant, and high-quality printed packaging.

A UV-cured ink that dries instantly under ultraviolet light and creates crisp, high-quality print results on a wide range of packaging materials.

A plant-based ink made with soybean oil, offering rich color output and a more sustainable printing option for carton packaging.

A standardized color-matching system used to achieve consistent, accurate brand colors across packaging, labels, and printed materials.

A full-color printing process using cyan, magenta, yellow, and black inks to create vibrant images, gradients, and detailed packaging artwork.
Real feedback from customers who trust us with their custom packaging.
Clear answers about ordering, artwork, production, materials and delivery.
If it's curved, tapered or irregular enough that a rectangular box either wastes space around it or lets it shift in transit, that's a functional reason. If the product itself is ordinary and the goal is shelf standout, that's a branding reason instead, and both are valid starting points for a quote.
It can. A rectangular box nests and stacks predictably by default, and a custom outline commonly doesn't, so factor that storage and handling cost into the decision alongside the visual benefit.
No. Foil, embossing, spot UV and lamination are all applied to the finished panels regardless of the outline they were cut into, so a custom shape doesn't narrow the finishing choices available on a standard box.
Orders start from 100 units.
No. A rough description of the product or the shape you have in mind is enough to start from, since design support helps develop that into a workable outline before anything goes into production.