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Here at Constan Packing, our CAD design department is always making samples for customers and prospects. In this post, we’re going to talk about how to make a rigid tray box with a pullout sleeve. It works well for VIP samples.

Rigid Boxes vs. Folding Cartons

A rigid box is a three-dimensional box made out of thick, stiff cardboard. It doesn’t collapse or fall apart. The rigid tray box contains four sides with one open side. This is where the sleeve slides in and out of either side. After putting it together, the tray can be filled with goodies.

A folding carton, on the other hand, can collapse. It’s like those white gift boxes you buy flat. Do a little maneuvering and it’ll be a complete box with a lid. Folding cartons typically have printing right on the cardboard. Rigid boxes tend to have printing on a separate wrap — fabric, paper, or leather — that can be attached to the plain box.

They can have special features such as a window, embossing, hinges, and compartments. A client has a lot of flexibility and can order small or large runs as it rarely has additional fees like other types of boxes that require heavy machinery.

How to Make Rigid Boxes with a Plain Ridge Tray

Step 1: Select the stock

We select the stock that is needed to make the components. The first being the tray with its two parts. One part is the tray base, which is made from a bending chipboard.

The second part is a thin litho paper that we will use to wrap around the base. In order to glue the wrap around the base, we use a machine called Emmeci MC2004. This machine will apply the glue to the base and press the wrap around the base inside and out. You can see the inside of the wrap glued to the inside in the picture.

Step 2: Die-cutting the sleeve

The sleeve is actually made from a solid bleached sulfate (SBS) board. Here, we die-cut the sleeve out of stock to scrap and send over to the finishing department.

Step 3: Put the parts together

The team that does the finishing glues this straight line and then they send it to the rigid team so that they may marry the two parts together. Then the box is ready to be loaded.

Branding with Rigid Boxes

Rigid boxes can look upscale or casual to match a company’s brand. Luxury brands like Tiffany and Chanel have been using rigid boxes for years. Companies may not consider using rigid boxes because of their tie with luxury brands. But they’re actually one of the most affordable options because of their adaptability.

Some companies select them so recipients can use them as a keepsake. Rigid boxes are easy to stack, handle, open, and display. You have many possibilities and all without the high price tag.