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Custom Rigid Boxes
Custom Printed Rigid Boxes
SunTop Printing manufactures custom printed rigid boxes for commercial orders with printed wraps, specified closures, and surface finishes.
The completed box holds its required shape; where a lid or closure is specified, it fits the formed structure; and the printed wrap and specified finishes remain in position after wrapping and forming.
A physical rigid-box sample lets you review the box shape, any specified closure, the printed wrap, and surface finishes before the commercial order is manufactured. Once confirmed, those details set the requirements for the commercial order.
Rigid Box Construction
SunTop Printing manufactures magnetic rigid boxes, collapsible rigid boxes, custom rigid drawer boxes, two-piece rigid setup boxes, book-style rigid boxes, and shoulder-neck rigid boxes. The differences can be seen in the completed rigid box—how the lid fits, how a magnetic box closes, how a drawer moves, how a fold-flat box returns to shape, and how a fitted insert holds the contents in position.
On two-piece rigid setup boxes, the lid fits evenly over the base after wrapping. The difference in lid-to-base position across the four sides is no more than 0.5 mm, and the lid and base continue to fit normally after the lid is removed and fitted again.
On shoulder-neck rigid boxes, the raised inner neck stays aligned with the lid and base when the box is closed. The difference in visible neck height around the four sides is no more than 0.5 mm. Rigid setup boxes are supplied fully formed.
Magnetic rigid boxes close evenly after wrapping and repeated use. After 5,000 opening-and-closing cycles, the magnetic closure continued to work normally, the lid-to-body gap remained below 0.5 mm, and both the lid and body remained flat.
On custom rigid drawer boxes, the difference between the visible side gaps of the drawer and sleeve is no more than 0.5 mm. With the specified insert and load in place, the drawer continued to move normally after 1,000 complete pull-out and return cycles, with no sleeve-edge or wrap changes that affected use.
Collapsible and foldable rigid boxes return to shape when re-formed. On a commercial fold-flat book-style rigid-box order, the printed-wrap grain followed the book-style hinge and folding direction. After 50 fold-flat and re-forming cycles, the rigid box could still be re-formed normally, and the condition of the wrap, corners, and glued areas did not affect re-forming.
When a fitted insert is specified, it holds the contents in position inside the box. EVA and EPE inserts are cut to ±0.2 mm; with the specified load in place, the contents remained in position inside the insert when the rigid box was inverted. SunTop also works with sponge, vacuum-formed trays, and die-cut paperboard inserts.
Rigid-box wrapping materials include printed coated art paper, textured or linen paper, kraft paper, metallic paper, PU leatherette, and fabric or book-cloth wraps. High-density greyboard commonly ranges from 1200 to 1800 gsm, approximately 2.0–3.0 mm thick. Board thickness and V-grooving determine the rigid structure and corner form, with 90° corners or 120° bevels used according to the box construction.
Rigid Box Quality
SunTop Printing keeps the rigid-box shape flat and stable after wrapping and forming, with clean wrapped edges and corners, the printed wrap aligned with the rigid-box structure, and specified surface finishes aligned with the artwork.
Across commercial rigid-box orders, the main formed dimensions remain within ±1.0 mm of the physical sample used for the order. On rectangular rigid boxes, the difference between the two diagonals is no more than 1.0 mm, with square corners and a flat, stable box shape.
The die-cut printed wrap is aligned with the rigid-box structure within 0.2 mm. After wrapping and forming, the printed wrap remains closely bonded to the greyboard with intact edges and corners.
For custom luxury rigid boxes, the printed wrap and surface finishes remain aligned after wrapping and forming.
On a commercial order of 26,000 fold-flat book-style rigid boxes, full-color printed wrapping was combined with soft-touch lamination, gold foil stamping, embossing, and spot UV. Multi-process registration was within ±0.15 mm.
Across the order, the printed artwork and specified finishes remained in position around wrapped edges, inner turn-ins, corners, the book-style hinge, and visible areas when the box was opened. After re-forming, the printed wrap and finishes continued to match the physical sample used for the order. After Sutherland® 2000™ rub testing, the printed wrap and surface finishes retained the required visual result.
After 12 months of storage, the printed wrap remained bonded to the greyboard, the lid and body remained flat, and the overall rigid-box shape remained stable.
Rigid Box Manufacturer
Rigid boxes are one of the Custom Printed Boxes manufactured by SunTop Printing. For rigid-box orders, SunTop completes printing of the wrap, greyboard V-grooving, gluing, wrapping, and forming in house.
Rigid-box manufacturing uses KOLBUS NM 101 for greyboard V-grooving, with Emmeci D640 and ZHONGKE ZK-900CS for wrapping and forming.
For applicable rigid-box structures, manufacturing capacity is 100,000+ boxes per day.
For the 26,000-unit fold-flat book-style rigid-box order, the boxes were supplied flat, and the customer confirmed satisfaction after delivery. SunTop has also completed an 80,000-unit magnetic rigid-box order manufactured and delivered to match a complete physical rigid-box sample.
Get a Custom Rigid Box Quote
Tell us what you know about your rigid-box project. A brief description is enough to start.
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