Posted on September 29, 2020 by Dennis Salazar

E-commerce Custom Shaped Boxes Are Memorable and Effective

unique custom die cut mailer by Salazar PackagingMost DTC, e-commerce boxes are square or rectangular and that is good. They are nice, simple, and easy for 3PL staff to form and pack. However, the downside is that unless you have an incredibly unique, attractive, exterior graphic design (more on that in my next post) they tend to look like everyone else’s box.

For the people who want something different, we have the capability to make other custom shapes on paperboard folding cartons, paperboard rigid wall boxes, and even corrugated shippers. You can always talk to us and let us know what you are thinking, and we can probably tell you the feasibility after a brief conversation. Here are two key differences that will require some discussion with you:

The purpose and application of your packaging    

Is the container you are considering going to be for retail display or as a shipping container? Is your primary concern presentation or protection? (see first “related post” below). Is it shipping via UPS, USPS, or FedEx or is it being hand delivered?  What do you envision in terms of graphic design?

Budget and quantity

As we have discussed before, volume usually helps determine what is and what is not possible.  See the second related blog post below. If you are looking to run 500 or even 1,000 boxes on your first run, some designs and prints may be cost prohibitive or simply not available due to a high minimum.

DTC Packaging with custom, unique shapes

If you are looking for a paperboard item such as a round, oval, triangular or just about any other shape, it can probably be accomplished easily using paperboard. These are most obvious especially with seasonal packaging such as Valentine’s Day, Easter, Halloween, and of course Christmas. Paperboard is more pliable, and it handles curved shapes that cannot be made in corrugated board.

custom shape die cut mailer with insertCorrugated board and designs like straight lines and can do virtually any angle needed. This post includes several different shapes that people do not see in their mailbox every day. One of my favorites is the “coffin” shaped box that makes a great carrier for anything from hot sauce to liquor.

Do you have a size and shape in mind? Our 1,000 MOQ for corrugated still applies on most designs, and keep in mind a custom cutting die (usually $800 to $1,000 will probably be necessary. For paperboard designs, the MOQ may be higher but the good news is that the tooling is generally less expensive.

Free application reviews

On a no cost, no obligation basis, we will be glad to discuss whatever size and shape you have in mind. Almost anything is possible for nearly any application. You never know until you ask.

Contact us at or call us at 630-551-1700 to share your desire and vision. One of our branded packaging experts will be glad to discuss your specific applications with you.


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