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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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.
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 |
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 Brands Trust Us
We are not just box manufacturers. We help brands package smarter, ship safer, and sell better, without unnecessary complexity.
- Packaging Specialists Industry-focused structures, not generic templates.
- Low MOQ Support Start small, scale confidently.
- Material-First Engineering Right board, right strength, right finish.
- UK & Global Fulfilment Flat packed, secure, and delivery-ready.
Our Process
Share your product size, quantity, and use-case.
We recommend structure, material, and finish.
Approve dieline or sample before production.
Manufacturing, quality check, and delivery.