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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.

Get Your Custom Quote

Share your box details and we will send your price.

1 Box Style
2 Material
3 Quantity
4 Contact

Choose Style

Why Choose Healey Packaging?

Premium printing, sustainable materials, fast turnaround, and reliable UK-wide service.

High Quality Printing

Sharp details, rich colours, premium print results.

No Minimum Order

Order from just 100 boxes — ideal for small runs.

Custom Sizes & Styles

Perfect tailored fit — at no extra design cost.

Eco-Friendly Materials

Recyclable, biodegradable, and FSC-certified.

Fast Turnaround

Quick production + reliable delivery times.

Free UK Shipping

Standard orders ship free across the UK.

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.

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

Explore Our Premium Packaging Options

Mix and match materials, printing methods, inks, finishes, and add-ons to build packaging that feels completely on-brand. Start with the material, then move through print and finishing to see what fits your product best.

Strong Corrugated cardboard sheets

Corrugated Cardboard

Shipping • E-commerce • Heavy items

Fluted middle layer for strength and cushioning. Ideal for mailer boxes, shipper cartons, and any product that needs extra protection during delivery.

DurableProtective
Eco Natural brown kraft board

Natural Brown Kraft

Eco brands • Food • Lifestyle

Rustic, uncoated look that feels honest and sustainable. Great for bakery, subscription boxes, and earthy lifestyle brands that want a natural tone.

RecyclableOrganic feel
Premium White SBS bleach card

SBS / Bleach Card

Beauty • Pharma • Retail

Bright white, smooth surface for sharp printing and rich colors. Perfect for cosmetic cartons, medicine boxes, and premium retail packaging.

High print qualityClean white
Luxury Black kraft packaging board

Black Kraft / Black Card

Luxury • Gifts • Apparel

Deep matte black stock that pairs beautifully with metallic foil. Best for luxury rigid boxes, apparel packaging, and special gift sets.

Premium lookFoil-ready
Flexible Digital printing press

Digital Print

Short runs • Variable data

Great for smaller quantities, seasonal packaging, or designs that change often. Fast setup with strong color output and no plate costs.

Low MOQFast
Classic Offset printing rollers

Offset Print

Larger runs • Brand colors

Industry standard for high-volume packaging. Ideal when you need consistent Pantone colors and the most economical cost per unit at scale.

Sharp detailCost-effective
Spot effects Scodix enhancement print

Scodix Enhancement

Tactile • Raised effects

Digital enhancement that adds raised UV, textures, and metallic-style effects to selected areas, creating a premium, touchable finish.

3D feelHighlight details
Gloss UV print on packaging

UV Print

High gloss • Rich color

Cured with UV light for instant drying and strong color density. Works well when you need vibrant prints on coated boards.

ShinyDurable
Standard CMYK ink cans

CMYK Process Inks

Full color • Gradients

Ideal for photography, gradients, and detailed artwork. Most packaging projects start here before adding special colors or finishes.

Full colorVersatile
Branding Pantone ink swatches

Pantone Spot Inks

Exact brand tones

Used when color accuracy is critical. Pantone inks lock in signature brand colors across different print runs and materials.

ConsistentOn-brand
Bold Screen printing ink layers

Screen Printing

Thick ink • Bold coverage

Screen printing lays down a thicker layer of ink, creating vibrant solid colors and strong opacity. Best for bold logos, solid shapes, and designs that must pop even on darker materials.

OpaqueVibrant
Eco Eco friendly vegetable inks

Soy / Vegetable Inks

Eco packaging

Lower-VOC options that support more sustainable packaging. Often paired with kraft stocks and minimalist designs.

Low VOCEco-minded
Matte Matte laminated box

Matte Lamination

Soft touch • Low glare

Gives packaging a smooth, elegant feel with reduced shine. A favourite for luxury, cosmetic, and tech products.

PremiumModern
Gloss Gloss laminated packaging

Gloss Lamination

Shiny • Eye-catching

Adds shine and extra ink protection. Works well for bold colors, retail shelves, and youth-focused brands.

ShinyScuff-resistant
Tactile Soft touch coated box

Soft-Touch Coating

Luxury feel

Creates a velvety, rubberised feel that makes customers want to hold the box longer. Ideal for high-end unboxing experiences.

VelvetyPremium
Highlight Spot UV gloss on box

Spot Gloss UV

Logo & details

High-gloss UV applied only to selected areas like logos or patterns, so they catch the light without making the whole box shiny.

ContrastLogo focus
Luxury Gold foil stamping on packaging

Foil Stamping

Gold • Silver • Custom

Metallic foil pressed into the board for instant shelf impact. Great for logos, borders, and badges on gift, cosmetic, and rigid boxes.

MetallicPremium detail
Raised Embossed packaging surface

Embossing

Raised detail

Embossing lifts selected artwork from the surface, giving logos, patterns, and brand marks a premium 3D raised effect that customers can feel instantly.

3D liftPremium texture
Depth Debossed packaging surface

Debossing

Pressed detail

Debossing presses artwork into the board, forming an elegant recessed impression. Works beautifully for minimalist luxury packaging and fine-detail branding.

IndentedLuxury
Windows Box with die-cut window

Die-Cut Windows

Show the product

Custom window shapes let customers see the product before they buy. Can be left open or backed with clear PET where needed.

RetailProduct focus

Loved by Real Customers

Liz Wheelhouse
★★★★★

“We reached out to Healey Packaging to help us create bespoke shaped boxes… the final product looked amazing and was very well received.”

November 18, 2025
Ash
★★★★★

“Very happy with the service and print quality. Patient with revisions and great communication. A very positive experience.”

September 18, 2025
Vanessa Scott
★★★★★

“The printing quality was excellent and Alex was incredibly helpful. I’ll definitely use Healey Packaging again.”

June 6, 2025
Adrian Tang
★★★★★

“Excellent service, very good quality and sharp printing. Highly satisfied with the results.”

May 7, 2025
G. Mitev
★★★★★

“Our custom boxes arrived exactly how we imagined. Great quality and friendly support from start to finish.”

April 21, 2025
Scott Anthony
★★★★★

“Really great branded hat boxes. Perfectly printed and excellent service. Will definitely return.”

April 14, 2025
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