The Surgery Is Now Open

Hi Max,

I wish I had to do projects like that in school — it sounds way more interesting than algebra! You’re absolutely right — die-cut packaging is a term you’ll hear a lot in the industry because it’s one of the key methods used in creating custom corrugated boxes.

There are two main ways to make boxes: one is an inline process, where a sheet of board is fed through a machine with blades and wheels that cut and score it as it goes. This is typically used for standard, off-the-shelf boxes because the sizes are already programmed into the machine, making it efficient for high-volume production.

The other method is die-cutting. This involves creating a large metal stamp with blades that's pressed into the board using a flatbed press. There's also a type called rotary die-cutting, where the design is printed onto a cylinder and rolled over the material. This is ideal for large-scale manufacturing because it’s faster and more consistent.

The big advantage of die-cutting is that it allows for highly customized designs. With CAD (Computer-Aided Design), you can create almost any shape or structure. This is perfect for companies looking for boxes that fit their products precisely. Internal dimensions are usually what matter most, since that’s where the product sits. External measurements depend on the thickness of the board.

Die-cut boxes can also include special features like self-locking bases, which make packing quicker, or tamper-evident seals for added security. Many of these designs are based on standards from the FEFCO (European Federation of Corrugated Board Manufacturers) guide, which lists over 900 box styles. These can be modified to suit specific needs, but they often serve as a great starting point for custom carton development.

Good luck with your project — it sounds like a really interesting topic. If you have any more questions, feel free to ask!

The Packaging Doctor

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