80% of packaging problems — product rattling, lids that don't close, freight you didn't need to pay — are decided at the dieline stage, before a single sheet is printed. We engineer the structure, prove it with a physical sample, then run production.
Not decoration — engineering decisions that show up on your P&L and on your damage claims.
Insert cavities cut to your product's actual dimensions, wall thickness where the load is. Glass bottles, jars, droppers, tools and multi-piece kits all get a different solution.
Right-sizing the box, dropping one board grade, switching a foil to cold foil, or shipping flat can cut 15–60% of unit or freight cost without changing what the customer sees.
Fold-flat rigid boxes and nested trays ship in a fraction of the volume of assembled boxes. We model the pallet, not just the box.
Send product photos, dimensions and target price. You get a dieline (PDF/DXF) and a structure recommendation — free, within 24h.
Plain white sample to test fit, or digitally printed sample to judge artwork and colour. Courier worldwide.
Fit check, colour proof against Pantone, drop and compression test in-house. We adjust the dieline before tooling.
Print, foil, die-cut, mount, inspect 100%, then photo/video QC report before the carton is sealed.
Most projects only need step 2. Sample cost is credited back against the bulk order.
| Sample type | What you get | Typical lead time | Cost |
|---|---|---|---|
| 3D render | Digital visual of the structure with your artwork mapped on. For internal sign-off. | 24h | Free |
| Plain sample | Unprinted box in the specified board and thickness — for fit, size and stiffness testing. | 24–48h | Free (courier only) |
| Digital printed sample | Your artwork printed and cut on the real structure, including one finish. | 3–5 days | USD 50–150, credited on bulk order |
| Production-match sample | Same board, same ink, same foil and lamination as the bulk run. For retail buyer approval. | 5–7 days | Quoted per structure |
Lead times are typical, not a promise — structures with magnets, moulded pulp or multi-layer inserts take longer. We confirm dates in writing before starting.
A sample that looks right on a desk is not the same as a box that survives a container. These checks run before tooling and before shipment.
Cutting dieline (PDF + DXF), 3D visual, recommended board and GSM, insert drawing, and a cost breakdown by component — so you can see exactly what each upgrade adds.
No. Dieline engineering and the structure recommendation are free — it's part of quoting. You only pay for physical samples, and that amount is credited back when you place the bulk order.
You do. The cutting file is yours to keep and reuse, including with another supplier. We don't lock structures behind tooling fees.
Yes. Send the AI/PDF/DXF and we'll run a fit and feasibility check first. If we spot a weakness — a lid that will bow, a base that needs more board — we'll tell you before printing, not after.
That's the normal case. Send the product dimensions (or the product itself) and we build the structure around it — including odd shapes, multi-piece kits and bottles with pumps or droppers.
Send one physical sample. We reverse-engineer board thickness, wrap, finish and insert, then quote a matched version — usually cheaper, since we can also suggest where the original is over-specified.
Photos, dimensions and target retail price are enough to start. Dieline and cost comparison back within 12 working hours.