Custom Flat Pack Boxes
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Elevate your packaging with custom flat pack boxes, crafted for durability and standout presentation. Choose your size and finish to match your brand. Place your order now and save with wholesale rates!
$0.74
UNLIMITED CUSTOMIZATION OPTIONS
A printing technique employing a plate to transfer designs onto paper. Ideal for extensive print jobs.
Plate-free digital printing transfers designs electronically, cost-effective for short runs.
Screen printing is a method using a mesh screen and stencil to transfer ink onto a substrate.
Quick-drying printing technique utilizing ultraviolet lights for ink curing, yielding a glossy finish.
Consisting of water-based pigments, Ensures top-notch color output with a 100% eco-friendly profile.
Fluorescent inks are vibrant, UV-reactive pigments that emit vivid colors under ultraviolet light.
Generate pure colors using specific ink formulas to consistently & precisely reproduce color in printing.
Produce metallic colors through precise ink formulations to replicate color in printing.
Premium bleached white paperboard, specially coated on one side to enhance printing & finishing.
Bleached white paperboard, coated on both sides to achieve superior printing quality and finishes.
Top-notch textured paper, perfect for adding a touch of style when wrapping up durable boxes.
A unique paper material showcasing a shiny or matte metallic laminated surface.
Bleached kraft paper crafted from a blend of new and recycled pulp, coated on both sides for optimal printing.
Kraft paper produced from a combination of new and recycled paper pulp, with coating on both sides for printing purposes.
Kraft paper dyed black, manufactured from a blend of new and recycled pulp, and coated on both sides for printing applications.
Crafted from recycled grey chipboard cardboard, also known as uncoated recycled paperboard, ideal for luxury rigid boxes.
Unique paper material showcasing a holographic laminated surface in either glossy or matte finish.
Grey chipboard, one-sided white cardboard with a smooth, printable surface, ideal for luxury rigid boxes.
Gloss lamination enhances visual appeal by applying a shiny finish, and protecting printed materials.
Matte lamination offers a non-reflective finish, providing elegant appearance to printed materials.
Made with a smooth lamination that feels like touching a peach, can choose between a satin or matte.
A UV coating is applied to a specific area and then cured using ultraviolet light to make it sturdy.
A transparent coating is applied using the CMYK printing technique, and it comes in gloss, satin, or matte.
A fast-drying coating that undergoes curing through ultraviolet light is offered in both gloss and matte.
In a printing method, dies are pressed onto the back of the material to create a raised motif.
A printing technique that involves pressing dies onto the front of the material to create a raised motif.
In foil relief printing, foil is transferred at high temperatures, often employing multiple colors.
Craft a die-cut shape with a plastic film layer, revealing a window to showcase the product inside.
We recommend the ideal material and add-ons like lamination, foiling, embossing UV, etc.
Get Free Design Support with your box 3d Renders or Send Your Design File for Printing.
Upon design approval, we’ll print and conduct quality checks before shipping the boxes to you.
Technical Specifications
| Dimensions | Available in Custom Sizes |
| Printing | CMYK, Pantone Color, Full Color & No Printing |
| Paper Stock | Eco-Friendly Kraft, Corrugated Cardboard & Premium Rigid Stock |
| Coating | Semi-Gloss AQ, Gloss UV, Matte UV & Spot UV |
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
| Custom Options | Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink |
| Proof | Digital Proof, 3D Mock-Up |
| Shipping | Shipped FLAT (Free Shipping Across USA & Canada) |
| Help | For further inquiries and Quotes, contact us or email at sales@cratpackaging.com |
Custom flat pack boxes from Crat Packaging ship and store flat, then fold into a finished box at the point of use — cutting shipping volume and warehouse space for brands that assemble packaging on demand. Built from corrugated or SBS board and printed with your full branding, these boxes are a practical choice for retailers, subscription programs, and businesses that pack products on-site rather than pre-boxing at the factory. We manufacture every box at our own US facility with low minimums and free design support.
Key Features of Our Custom Flat Pack Boxes
- Ships and stores flat — reduces freight volume and warehouse footprint versus pre-assembled boxes.
- Tool-free assembly — locking tabs and pre-scored folds let staff build a box in seconds.
- Full-color branding — CMYK or PMS printing on every panel, inside and out.
- Durable board options — corrugated for shipping strength or SBS paperboard for retail presentation.
- Custom die-cut shapes — mailer, tray, or auto-lock bottom styles built to your product.
- Space-saving logistics — cuts pallet count and storage costs for high-volume operations.
- Low MOQ — order as few as 100 units per run.
Specifications
| Attribute | Details |
|---|---|
| Box Style | Auto-lock bottom, tuck-end, or tray-style flat pack, folds flat for shipping |
| Dimensions | Fully custom, built to your product |
| Material | Corrugated E/B-flute or SBS paperboard |
| Thickness | 150–350 GSM board or corrugated flute |
| Printing | CMYK, PMS spot color, digital or offset |
| Finishing | Matte or gloss lamination, spot UV, foil stamping |
| Add-ons | Locking tabs, hang holes, window cutouts, inserts |
| Minimum Order | 100 units |
| Turnaround | 10–15 business days (8 business days expedited) |
| Setup / Plate / Die Charges | Free |
Customization Options
Sizes and Styles
Flat pack boxes are built with pre-scored fold lines and locking tabs that snap into an auto-bottom, tuck-end, or tray-style box in one motion — no tape or glue required at assembly.
Materials
Choose corrugated board for shipping-grade strength, or SBS paperboard for a smoother, retail-ready print surface. Kraft stock is available for a natural, sustainable finish.
Printing and Finishes
Full-color CMYK or Pantone printing runs across every panel, so branding stays intact once the box is folded. Matte or gloss lamination, spot UV, and foil stamping are available for a premium look.
Add-Ons
Add die-cut window panels, hang holes for pegboard display, or corrugated inserts that fold in alongside the box for a complete flat-pack kit.
Industries & Use Cases
Custom flat pack boxes suit retailers and fulfillment centers that assemble packaging on demand, subscription box programs, furniture and home-goods brands, and any operation looking to cut storage space and freight costs on packaging inventory.
How to Order
- Request a free quote with your product dimensions, order quantity, and fold style preference.
- Work with our design team at no cost to finalize the dieline and artwork.
- Approve a proof before production begins.
- Production runs 10–15 business days (8 business days expedited).
- Boxes ship flat, ready for on-site assembly.
Why Wholesale Buyers Choose Crat Packaging
Crat Packaging manufactures every flat pack box at our own US facility, with no setup, plate, or die charges and free design support on every order. Minimums start as low as 100 units, and bulk pricing starts from around $0.75 per unit, depending on size, material, quantity, and finishing.
Frequently Asked Questions
How does a flat pack box assemble?
Pre-scored fold lines and locking tabs let staff fold the box into shape by hand in seconds, without tape, glue, or tools.
What is the minimum order?
Our minimum order for this packaging style is 100 units.
Do flat pack boxes cost less to ship than pre-assembled boxes?
Yes. Because they ship flat, you fit significantly more boxes per pallet or carton, which typically lowers freight cost per unit compared with pre-formed boxes.
Can I get free design help?
Yes. Our design team builds your dieline and artwork at no charge, and you approve a proof before production.
What materials are available?
We offer corrugated board for shipping strength, SBS paperboard for retail presentation, and kraft stock for a sustainable look.
How long does production take?
Standard turnaround is 10–15 business days from proof approval, with 8-business-day expedited production available.
Ready to cut storage and shipping costs with packaging that assembles on demand? Get a free quote from Crat Packaging today.
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