Structures and when to use them
- Rigid box — greyboard wrapped in printed paper. The premium default for gift sets and skincare. Does not fold flat, so freight volume is high.
- Folding carton — printed card, ships flat, cheapest per unit at volume. The standard for single-SKU retail.
- Magnetic closure — rigid box with embedded magnets. Popular for subscription and influencer kits.
- Drawer and sleeve — two-piece formats that read as considered and cost less than a full magnetic box.
Board weight and wrap quality
Rigid boxes use greyboard from 1,200 to 2,000 gsm. Below 1,200 the box flexes and the corners soften; above 1,800 the weight becomes a freight problem. The wrap is 128–157 gsm art paper, and the wrapping step is where quality is won or lost: bubbles, misaligned seams and lifted corners all come from this stage, not from the printing. Ask for a photo of the corner construction on the sample.
Finishes that hold up
Foil stamping and embossing are the two finishes that consistently read as expensive. Matte lamination looks good and scratches; soft-touch coating looks better and scratches more. Spot UV adds contrast and is the finish most likely to crack along fold lines. If the box will travel in a mailer, specify a scuff-resistant lamination and test a filled box through a drop — uncoated stock marks instantly against corrugated.
MOQ, die cost and timing
Folding cartons usually start at 1,000–3,000 pieces; rigid boxes at 500–1,000 because they are assembled by hand. Die cutting costs USD 100–300 and is a one-off. Sampling takes 7–10 days for a white dummy, 12–18 days for a printed proof. Production runs 15–25 days. Colour matching across board and lamination is the most common delay — approve a physical proof, never a PDF.