Box Templates & Structural Packaging Styles

A box template describes the general structural style, such as straight tuck end, auto-lock bottom, sleeve or tray. A production dieline is created for a specific size and specification and shows the exact panels, cut lines, crease lines, glue areas and artwork positions required for manufacture.

Start with the finished product dimensions and weight, then consider packing speed, protection, opening method, presentation and distribution. Lightweight retail products may suit tuck-end cartons, while auto-lock bottoms can reduce assembly time and reinforced or corrugated structures may be more appropriate where additional support is required.

Yes. Structural styles can be adapted around the finished product rather than being limited to a fixed stock size. The final dimensions should also account for board thickness, practical clearance, closure geometry and any inserts or internal support required.

Straight tuck end, reverse tuck end, auto-lock bottom, sleeve, tray, lid-and-base and display structures can all suit retail applications. The best option depends on product weight, shelf presentation, packing method, customer access and the required opening experience.

Yes. Board construction and thickness can affect crease allowances, panel clearances, closure fit and locking features. A dieline developed for lightweight folding board should therefore not automatically be transferred unchanged to substantially thicker board or corrugated material.

Artwork should be positioned after the structure, dimensions and material have been confirmed and the production dieline has been prepared. Designing against the final dieline helps ensure logos, text, barcodes and graphics are correctly positioned around panels, folds and cut edges.

Yes. An existing dieline or structural concept can be reviewed against the intended product and specification. Dimensions, folds, panel construction, material suitability and artwork positioning should be checked before sampling or production rather than assuming an existing file is immediately production-ready.

Yes, where the products have compatible dimensions, weights and packing requirements. Keeping an approved structure consistent across related SKUs can simplify repeat production, while artwork or dimensions can be adjusted where the individual product requires it.

Healey Packaging offers no minimum order requirement for custom packaging. Standard production is typically 7–10 working days after artwork approval, although specialist structures, materials, sampling or finishing requirements can affect the final schedule.