Lip Shaped Boxes.

Yes, a bespoke steel rule die, because no stock cutting die fits an irregular outline. The first order carries a one-time die charge and every reorder after it uses the same die at no extra cost. Read the first quote with that in mind: the tooling amortises across the run and every run that follows.

Tooling adds 5 to 7 days to the first order only.

About 3mm minimum radius at any internal corner. Tighter than that and the board fibre cracks on the fold. The points of the lip outline get softened slightly, enough to fold cleanly but not enough for a customer to notice. Heavier board holds the convex curve better, so 24pt SBS is preferred above roughly 4 inches wide.

FBB is marginally more forgiving through tight die-cut curves if cost matters.

Because an irregular outline wastes press sheet, typically leaving only 60 to 70 percent of it as boxes. A rectangle nests edge to edge and a lip shape does not. Mirrored interlocking on the layout recovers some of that waste, so ask about nesting when you send the artwork.

For a gifting tier, a rigid chipboard version with a magnetic close avoids the folding compromise on the curves entirely.

Gloss lamination in a saturated red. A wet, dense red is what makes the outline register instantly. Hot foil run along the die-cut edge defines the shape and hides minor cutting variance, which is useful on a curved outline. Spot UV over a matte field suggests shine on the lip while the surround stays flat.

Soft-touch reads as a matte lipstick finish instead, a deliberate alternative. An emboss across the curve needs heavier board so the outline does not distort.

Between 3 and 5 inches across for most gift and kit formats. There is no standard size because the dieline is drawn from scratch around whatever goes inside. Depth follows the contents, and a metallised board suits the mirror-red finish this shape is usually specified in.

Send the products or their dimensions and we'll draw the outline to fit, then send a white sample cut on the new die.

500 boxes, the same floor as our rectangular cartons. The die charge sits on top of the first order rather than changing the quantity. Because the die is reusable, a second order of 500 costs noticeably less per box than the first.

We'll run up to 100,000 on the same die.

7 to 10 business days for production, plus 5 to 7 days for the die on a first order. Reorders skip the tooling wait. A rush at 5 to 7 business days applies to production only. A sample takes 5 to 7 business days and we would always cut one on a new shape before printing.

Sample charges are credited against the bulk run, and we deliver USA-wide.

24pt SBS on anything over about 4 inches wide, and 18pt on smaller outlines. The heavier caliper holds a convex curve without buckling. Both recycle as paperboard, though a gloss film lamination or a metallised surface takes the pack out of a single-material claim.

The rigid chipboard version wrapped in printed paper is the answer where the outline must be crisp and the box will be kept.