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Custom Die cut Boxes

Not every product fits neatly into a standard box — and not every brand wants one that does. Our custom die cut boxes give you full control over how your packaging looks, feels, opens, and performs. Whether you need a branded mailer, a secure product fit-out, or a retail-ready display with shaped cut-outs, we’ll help you build a box that does the job properly. With more than 1,000 UK businesses trusting Healey Packaging, we’ve got the experience to help you get it right the first time — and the scale to grow with you.

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Why Choose Healey Packaging?

We combine expert printing, sustainable materials, and flexible options to support brands of every size — all made right here in the UK.

High Quality Printing

High Quality Printing

Get rich colours, sharp details, and premium finishes on every custom box we print.

Low Minimum Order

No Minimum Order

Order as few as 100 boxes — ideal for startups, test runs, and small businesses.

Custom Sizes & Styles

Custom Sizes & Styles

Get expert help to refine your box layout and branding — at no extra cost.

Eco-Friendly Packaging

Eco-Friendly Packaging

Choose from recyclable, biodegradable, and FSC-certified materials.

Fast Turnaround

Fast Turnaround

Quick production and delivery times to meet urgent deadlines.

Free UK Shipping

Free UK Shipping

Enjoy hassle-free shipping across the UK on all standard orders.

Product Specification

Dimension (L + W + H) All Custom Sizes & Shapes
Quantities No Minimum Order Required
Paper Stock 210gsm, 250gsm, 280gsm, 300gsm, 350gsm, 420gsm, 460gsm, 500gsm, Bleach Card (SBS) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Etc.
Printing No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors
Finishing Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling
Included Options Die Cutting, Gluing, Scoring, Perforation
Additional Options Eco-Friendly, Recycled Boxes, Biodegradable
Proof Flat View, 3D Mock-up, Physical Sampling (On request)
Turnaround 7 – 10 Business Days, RUSH
Shipping FLAT

What Die Cut Packaging Can Do for You?

Die cutting isn’t just for style — it’s a practical way to improve how your box protects, presents, and performs. We design custom die cut packaging around your product, so there’s no wasted space, less risk of damage, and a much better fit from box to customer.

Here’s how our clients use it:

  • Corrugated die cut boxes for strength and safe delivery
  • Die cut inserts to keep fragile products locked in place
  • Shaped cut-outs or handles for custom retail display boxes
  • Foldable mailer-style die cut boxes with built-in flaps
  • Custom printed die cut boxes with brand artwork or messaging

Whether you’re selling hardware, cosmetics, tech, or food — we’ll make sure the box supports your product from warehouse to doorstep.

Structure and Strength That Prevents Returns

Fit matters. Boxes that are too loose cause rattling and damage. Boxes that are too tight crush the product or create friction at unboxing.

Our custom die cut boxes solve that by being precision cut to your actual product specs:

  • Keeps items secure and separated
  • Reduces movement during transit
  • Protects high-value or breakable goods
  • Supports multi-item kits or stackable layouts
  • Improves unboxing experience by making everything feel intentional

This also helps reduce returns caused by damage, confusion, or presentation issues — and helps your customer remember the brand behind the packaging.

Print, Finish, and Full Branding Control

From clean and minimal to bold and branded, your box should reflect your business. We offer full control over design with:

  • CMYK or Pantone colour models
  • Digital and Offset printing
  • Matte, gloss, or soft-touch finishes
  • Spot UV and foil accents for logos
  • Custom printed die cut boxes with messaging inside and out
  • Tear-strip openings, shaped windows, or locking flaps

Need your box to double as a gift set, a retail tray, or a launch kit? We’ll help you get the cut and finish just right.

Eco Options That Still Do the Job

We know many UK brands are aiming to reduce waste — without cutting corners on protection or branding. Our die cut packaging can be made with:

  • Recyclable or compostable board
  • FSC® certified materials
  • Soy-based, low-migration inks
  • Plastic-free inserts or window films

Got sustainability targets? Maybe you’re trying to cut out plastic, or maybe you’re aiming for packaging that can be recycled end to end. Either way, just tell us what you’re working on — we’ll figure out the right materials and box style without making it a hassle.

Built to Scale — From One SKU to Full Rollout

We’ve been a trusted die cut boxes manufacturer for 10+ years, helping brands grow from local launches to full-scale national distribution. Whether you’re ordering 100 pieces or planning for bulk die cut boxes across multiple SKUs, we’ve got the infrastructure to support you.

  • Low minimum orders (starting at 100 units)
  • Fast turnaround — 7–10 working days
  • Split runs across SKUs or sizes
  • Die cut boxes wholesale pricing for larger quantities
  • UK production + delivery with hands-on support

Need packaging for an awkward shape, limited-edition run, or retailer-ready display unit? We’ve probably built something like it before — and we’ll walk you through it.

Questions Brands Ask Before Ordering

What’s the difference between regular and die cut boxes?

Die cut boxes are made using a custom cutting tool that allows for unique shapes, windows, or folds. You’re not limited to standard templates — we build them to your spec.

Can I use die cut boxes for shipping?

Yes — especially with corrugated die cut boxes. They’re sturdy enough for courier delivery and can be made with locking tabs or reinforced edges.

What’s the lead time on custom die cut boxes?

Usually takes about 7 to 10 working days once you’ve signed off the artwork. If you’re on a tight deadline, just give us a heads-up — we’ll see what we can do.

Do you offer samples or prototypes?

Absolutely. We can provide printed or blank mockups so you can test size, structure, and fit before committing.

Can I get printed inserts with my die cut packaging?

Yes — we can create inserts, holders, or compartments with custom printing to match the rest of your box.

Why Packaging Fit Matters More Than Ever?

Customers notice the little things — how the box opens, how the product sits inside, whether anything moves around in transit. A well-fitted box does more than protect; it shows the customer you care. That’s what keeps people coming back, and that’s what die cut gets right.

Let’s build something that holds your product properly — and leaves the right impression.

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