Hexagon Boxes.

Most folding hexagons close with a petal-fold base, where six curved flaps overlap and lock into one another. It needs no glue on the packing line and the blank still ships flat. The catch is that a 120 degree fold locks more softly than a right angle, so the base ends up carrying most of the box's stiffness.

For heavier contents we'd go with a glued crash-lock bottom, or move to a rigid build where the base is a separate wrapped panel.

Pick folding blanks for retail volume and rigid builds for gifts that will be kept. A folding hexagon is cut from one sheet of SBS or kraft board, ships flat and folds up on your bench. A rigid hexagon has chipboard walls wrapped in printed art paper and arrives made up, with a separate lid that has to meet all six edges.

The rigid version costs more per unit and in freight. Many candle and honey brands run both from the same artwork, one for the shelf and one for the gift season.

It will once a collar insert is fitted to hold it in the middle. A round item leaves six small voids at the corners, and without an insert the jar slides across them and scuffs against the walls in transit. A paperboard collar cut to the diameter stops that movement.

Send us the diameter and height with any lid or pump fitted, and we'll cut the collar to that and size the hexagon around it.

We lay the six panels out as one continuous wrap and design across them as a band. On a 6 inch hexagon each face is narrow, so a logo placed over a fold breaks in half. Most designs put the main mark on a single panel and run a pattern, often a honeycomb register, around the others.

CMYK and Pantone print are both available, with hot foil, embossing, spot UV or soft-touch lamination on top. We don't offer window patches or holographic film on this shape.

Hexagons are measured across flats, meaning the distance between two opposite parallel walls, and then by depth. Across corners is always the larger figure, so quoting from the wrong one gives you a box that doesn't fit. A common size is 6 inches across flats by 3 inches deep.

Nested sets are worked out as a series, with each box sized to sit inside the next one with a little clearance, so we draw the whole set together.

The run starts at 500 hexagon boxes. That figure holds for folding blanks and rigid builds alike, and the same die takes you up to much larger programme volumes. For a nested set, we quote each size in the set so you can see where the cost sits.

Design and dieline help costs nothing, and we ship anywhere in the USA.

Production takes 7 to 10 business days from artwork approval, and a rush slot shortens that to 5 to 7. A physical sample can be made first in 5 to 7 business days. On a new six-sided die we'd recommend it, because lid fit across six edges is much easier to judge in the hand than on a proof.

The sample fee comes off the bulk order once you go ahead.

Very little, because hexagons tessellate and pack against each other with no gaps. Each wall meets its neighbour flat on, so a case or a shelf row fills cleanly, where a run of cylinders leaves dead space at every contact point. Folding blanks also arrive flat, which keeps inbound freight down.

SBS and kraft versions go into paper recycling. Rigid wrapped builds tend to be kept and reused, which is part of why brands pay for them.