What is a die-cut box?

A die-cut box is packaging that has been cut and creased using a custom steel-rule die — a precision cutting tool shaped to the exact outline of your box design. The die simultaneously cuts the outer shape and creates the fold lines (creases) needed to assemble the box.

How die-cutting works:
1. A flat sheet of board is placed under the die
2. The die presses down, cutting through and creasing the board simultaneously
3. The cut sheet (called a blank) is stripped of waste material
4. Blanks are glued where needed and shipped flat
5. You or your customer folds them into boxes

Why die-cutting matters:

• Enables any box shape, not just rectangles


• Creates precise, clean edges and fold lines


• Allows for features like windows, handles, tuck-in tabs, and magnetic closures


• Essential for complex retail packaging shapes

Die-cut box types:


• Standard RSC (Regular Slotted Container) — the classic shipping box


• Tuck-end cartons — retail boxes with folding top and bottom


• Window boxes — with clear PET window cut-outs


• Shaped boxes — hexagonal, triangular, or custom profile


• Display boxes — with tear-away fronts or pop-up displays

Die cost:
For offset-printed packaging, a die is required (typically £80–£300 depending on complexity). Digital printing with a plotter cutter avoids a traditional die, making it more economical for short runs.