Whether you need custom packaging for wedding favors, business promotions or gift-giving, custom gable boxes allow you to create highly customized packaging solutions. Their classic triangular design complements a wide variety of products while giving your brand a polished, premium appearance. Let’s explore how to design and produce high-quality custom gable boxes.
Design Considerations
The first step is considering your design requirements. Determine the size needed to fit your items, as well as colors, graphics and additions like ribbons, embossing or cellophane wrapping. Sketch rough dimensions and ideas on paper. Keep in mind any printing processes or embellishments that may affect sizing. For example, foil stamping adds thickness.
Materials Selection
Gable boxes are commonly made from cardstock or thicker paperboard. Materials impact durability, printing options and budget. Some choices are:
C1S or C2S cardstock (250-500 gsm): Economical, ideal for one-time use items. Best suited for digital printing.
SBS or SC paperboard (500-1000 gsm): Provides additional rigidity and thickness. Can be die cut, printed or foil stamped. Holds embellishments well.
Specialty papers like vellum, metallic or linen: Add unique textures but cost more.
Foil laminated cardstock: Creates an elegant shine at higher cost than uncoated materials.
Design the Template
Export your design to Illustrator or another vector program to create a template at exact dimensions. Draw shapes for base, sides and lid with overlapping flaps indicated by dashed lines. Consider future bleed, scoring and die line markings during template design. Have it proofed before moving to production.
Order Digital Proofs
To really see how your design will look printed, order digital color proofs on actual materials at scale. This catches issues before production begins. Proofs allow modifying as needed.
Select your Manufacturer
Research printers that specialize in folding carton and cardstock production. Request samples of their gable box construction capabilities as well as price quotes based on your template, materials chosen and quantities required. Factors like set up fees, minimum order amounts and fast turnarounds impact cost estimates.
Specify Production Details
Accurately communicating production specs ensures a smooth process:
- Materials type and caliper/gsm
- Print process: Digital, flexo, litho, foil stamping etc.
- Spot UV coats, embossing, die cuts required
- Quantity, delivery date needed
- Template file format, color profiles used
- Quality assurance samples required
- Schedule a Pre-Production Proof
A press proof on materials mimicking final production is essential to catch any issues before a full run. Inspect for print quality, dimensional accuracy and function. Request revisions until approved.
Packaging Options
Custom gable boxes can be produced flat or ship assembled ready for filling. Consider:-
Flat: Saves on assembly costs, requires in-house setup. Great for small runs.
Full assembly: Includes scoring, creasing, gluing flaps together by printer. More expensive but eliminates in-house labor.
Partial assembly: Some setup like gluing sides together saves assembly time vs fully flat.
Quality Control
Close communication and inspection throughout production is key to avoiding delays or reworks. Request samples of printed materials, box components and assembled packs for final sign off before bulk production begins. Allow time for revisions if needed.
Finishing Touches
Add those special touches like custom ribbons, fillers or labels at time of assembly. Consider inclusion of your brand message or use instructions. Ensure careful quality control and safe packaging for shipping your finished custom gable boxes complete with delighted customers inside!
With careful preparation and collaboration between your creative vision and a reputable manufacturer, beautifully customized gable boxes become an attainable promotional material to support your brand, product or event.
