UK-Wide Delivery
Custom Packaging — No Minimum Order Flexible quantities for launches, growing brands and repeat orders.
Free Artwork Check Your artwork is reviewed before production begins.
Need Custom Packaging? Request a Quote
Starting From: £0.41
Final price depends on material, size and quantity.

Custom Die cut Boxes

Made to Order Custom Printed No Minimum

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.

Choose Your Box Style

Select the packaging style that best suits your product and brand.

Description

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.

  • No minimum order quantity
  • 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.

Specifications
Dimension (L + W + H)All Custom Sizes & Shapes
QuantitiesNo Minimum Order
Paper StockSBS, Kraft, Corrugated, Rigid Board
PrintingCMYK, PMS, Digital, Offset
FinishingMatte, Gloss, Foil, Embossing, Debossing, Spot UV
Included OptionsDie Cutting, Gluing, Scoring, Perforation
Additional OptionsEco-Friendly, Recyclable, FSC Options
ProofFlat View, 3D Mock-up, Physical Sampling On Request
Turnaround7–10 Working Days After Artwork Approval
ShippingFree shipping to the UK and USA.
Customisation

Explore your customisation options

Choose the options for your packaging. Final materials, printing and other details are confirmed with your quote.

Materials

SBS Board

SBS Board

Smooth white board for premium printed retail packaging.

Kraft Board

Kraft Board

Natural board for recyclable, earthy and understated packaging.

Corrugated Board

Corrugated Board

Fluted board for ecommerce, shipping and added product protection.

Rigid Board / Black Card

Rigid Board / Black Card

Premium stock for gift, luxury and presentation packaging.

Printing Methods

Digital Printing

Digital Printing

Fast setup, great for smaller quantities and designs that change frequently. Strong colour output without plate costs.

Offset Printing

Offset Printing

Best for scale. Consistent results run after run, especially when brand tones and fine detail matter.

Scodix Enhancement

Scodix Enhancement

Adds raised UV and tactile highlights to chosen areas. Ideal when packaging needs a premium touch people notice instantly.

UV Printing

UV Printing

UV-cured inks dry instantly and hold colour density well. Great for coated boards and vibrant retail graphics.

Inks

CMYK Process Inks

CMYK Process Inks

The go-to for full colour artwork, photography, and complex graphics. Great base before special effects.

Pantone Spot Inks

Pantone Spot Inks

When consistency is non-negotiable. Locks in signature brand colours across materials and runs.

Screen Printing

Screen Printing

A heavier ink laydown for bold logos and high opacity. Great for darker stocks and simple, confident marks.

Soy / Vegetable Inks

Soy / Vegetable Inks

A cleaner alternative often paired with kraft stocks and minimal design. A solid fit for eco-led packaging projects.

Finishing

Gold Foil

Gold Foil

Warm metallic detail for logos, names and premium accents.

Silver Foil

Silver Foil

Clean metallic highlight for luxury and technical branding.

Spot UV

Spot UV

Gloss contrast applied to selected artwork areas.

Embossing

Embossing

Raised texture for tactile logos and brand marks.

Debossing

Debossing

Pressed detail for understated depth and texture.

Soft Touch

Soft Touch

Smooth tactile coating for premium handling.

Matte Lamination

Matte Lamination

Low-shine surface for modern, refined packaging.

Gloss Lamination

Gloss Lamination

Bright protective surface for stronger colour impact.

Add-ons

Inserts

Inserts

Hold products neatly in place during display and shipping.

Window Patching

Window Patching

Show the product while keeping packaging structured.

Die-Cut Shapes

Die-Cut Shapes

Create custom openings, contours and display details.

Handles

Handles

Add carry-friendly structure for selected box styles.

Sleeves

Sleeves

Add a branded outer layer around trays, boxes or products.

Dividers

Dividers

Separate multiple items inside one package.

Ribbons

Ribbons

Add a gift-ready finishing detail where suitable.

Hang Tabs

Hang Tabs

Support selected retail display requirements.

FAQs
Support before production

A clearer route to your custom packaging.

Work through the size, material and print details with Healey Packaging before your order moves into production.

Share your product dimensions, quantity and delivery requirements when requesting a quote.

Product fit

Choose dimensions and a packaging format around your product and packing method.

Material options

Compare material options for presentation, product weight and day-to-day handling.

Printing for your brand

Specify your colours, artwork and finishing details for a coordinated printed pack.

Artwork guidance

Check dielines, print areas and artwork requirements before approving production.

Flexible quantities

No minimum order. Share the quantity you need when requesting your quote.

UK delivery planning

Tell us your delivery postcode and deadline so we can plan your order.

From our customers

Real feedback.
Thoughtful packaging.

In our customers’ own words. Selected excerpts from company reviews on Trustpilot.

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Can’t recommend the company enough, especially Alex who worded with me patiently all the way.…

Patrick Hennessy

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Quick and thorough responses from Alex. Delivery was also fast, and within the lead time they gave, I would recommend.

Iona

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I had a great experience working with Healey Packaging, I love my new candle boxes.…

Lisabel Biscaldi

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We had a deadline they needed to meet for me and they did.…

Jason Hart

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Had a very good experience with Healey. This is the second time we have used them…

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Great customer service, needed a quick turn around and assistance for custom packaging for my brand,…

Zeeshan Iqbal

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I looked through about 100 unhelpful suppliers, then found Healey Packaging.…

Max Faulkner

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Great quality product and excellent service from Alex.

QCL Scientific

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Feedback relates to Healey Packaging and its service, rather than a rating of an individual product.

Our Packaging Projects

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