Flat Pack Boxes
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Custom flat pack boxes that ship flat and fold together by hand in seconds, saving warehouse space and freight cost.
$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 |
Flat pack boxes ship flat and assemble by hand in seconds, freeing up the warehouse space that pre-glued cartons eat away at. Crat Packaging manufactures these fold-and-lock boxes in custom sizes and print finishes for brands that need dependable, tool-free assembly without sacrificing strength or shelf appeal.
Flat Pack Boxes Specifications
| Box Style | Auto-lock bottom, tuck-top, or lid-and-base construction |
| Material | Corrugated, SBS paperboard, or kraft, 14pt–200gsm |
| Assembly | Tool-free, folds and locks by hand in under a minute |
| Best For | Retail, e-commerce, subscription, and storage use |
| Print Options | Offset, digital, or flexo up to 6 colors, plus foil and spot UV |
| Order Volume/MOQ | From 100 units for samples to full truckload runs |
| Shipping | Nested flat for compact freight, ships nationwide |
What “Flat Pack” Means
These boxes arrive die-cut and creased but unfolded, staying flat until someone folds and locks the blank into shape. There’s no glue gun, no tape gun, and no pre-built shell taking up pallet space. One blank becomes one finished box the moment staff need it.
Why Businesses Choose This Format
A thousand pre-glued boxes need real square footage; a thousand flat blanks need a fraction of that. Freight costs drop too, since a truck carries far more flattened blanks than assembled cartons.
Who Buys This Style
We supply retailers, e-commerce fulfillment centers, subscription companies, contract packagers, and event organizers who need boxes on hand without a room dedicated to pre-built inventory. Many pair flat pack cartons with our custom corrugated boxes line for heavier shipments.
Consistent, Repeatable Assembly
Locking tabs and scored creases are engineered so the box folds the same way every time, with no learning curve for new staff and predictable strength once assembled.
An Eco-Conscious Choice
Most builds use recyclable corrugated or kraft board, and a 2025 McKinsey survey found that over 60% of U.S. consumers pick green packaging when they have the choice. A recyclable, low-footprint box supports that preference.
Custom Print and Format Options
Every box can carry your logo and brand colors, from single-color kraft printing to full-color offset with foil stamping or spot UV. We engineer custom dimensions rather than stock sizes only.
Why Order From Crat Packaging
- US-based manufacturing with predictable turnaround
- Custom sizing engineered to your exact product
- Low minimums so new brands can test before scaling
- In-house print team for accurate branding
- Dedicated account support from quote to delivery
- Structural samples available before a full run
How to Order
- Share your product dimensions and target quantity
- Review a structural proof and pricing
- Approve artwork and print finish
- Receive your flat-shipped order, ready to fold
Frequently Asked Questions
Do these need glue or tape?
No, locking tabs and scored folds hold them together by hand, though tape can add security for heavier loads.
How does this differ from flat pack boxes with lids?
This page covers the general format across base styles; the lidded version uses a separate lid piece instead of a tuck-top or auto-lock closure.
Can I use these for retail packaging?
Yes, we print full custom branding for retail shelves, e-commerce shipments, and point-of-sale use.
What sizes are available?
Any custom dimension, plus common stock sizes for faster turnaround.
Are they strong enough for shipping?
Yes, when specified in corrugated stock at the right flute profile for standard parcel handling.
What’s the minimum order?
Around 100 units for sampling, scaling to pallet and truckload quantities for established programs.
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