Custom Cardboard Boxes Made to Your Size
Can't find a stock cardboard box that fits your product properly?

 

Create your own.

 

ASC Direct's online Box Builder allows you to order custom cardboard boxes manufactured to the internal dimensions you need, rather than choosing the closest size from a range of standard boxes.

 

Enter your required length, width and depth, choose your box style and cardboard grade, select your quantity and get an instant online price.

Custom-sized boxes are available from just 25 boxes, making made-to-measure packaging accessible whether you're a small ecommerce business, launching a new product or ordering packaging in larger quantities.

 

Why Choose Custom-Sized Cardboard Boxes?
Stock cardboard boxes can be an excellent option when you find one that fits your product well.

 

But when the closest stock box is considerably larger than your product, you may end up paying for packaging you don't really need.

 

An oversized box can mean more empty space, more void fill, more storage space and more opportunity for the contents to move during transportation.

Custom-sized packaging takes the opposite approach.

 

Start with your product and build the box around it.

 

This can help you:

- Reduce unnecessary empty space
- Reduce the amount of void fill required
- Create a more consistent packing process
- Make better use of packaging storage space
- Keep products more securely positioned
- Create packaging specifically for unusual, long or awkwardly sized products

Right-sized doesn't mean tight-sized. Fragile products still need sufficient room for whatever protective packaging they require.

 

How Does the ASC Direct Box Builder Work?
Creating a custom cardboard box online is straightforward.

 

1. Choose your box style

Select the FEFCO box style most appropriate for your product, including conventional cartons, overlapping-flap boxes and wrap-style boxes.

 

2. Enter your internal dimensions

Enter the required:

Length × Width × Depth

in millimetres.

The dimensions entered into our Box Builder are internal dimensions, representing the approximate usable space inside the finished box.

 

3. Choose your cardboard strength

Select an appropriate board grade for your product, including Single Wall, Double Wall and Heavy Duty options where available.

 

4. Choose your colour and printing options

Depending on the box style and specification, you can select from available colours and printing options.

 

5. Select your quantity

Order custom-sized cardboard boxes from just 25 boxes, with quantity discounts available on larger orders.

 

You'll see your price online, so there's no need to submit your dimensions and wait for a bespoke quotation.

 

Are Box Builder Measurements Internal or External?
The measurements entered into the ASC Direct Box Builder are internal dimensions.

For example, entering:

400 × 300 × 200mm

 

means you're requesting approximately 400 × 300 × 200mm of usable space inside the box.

 

The finished external dimensions will be larger because corrugated cardboard has thickness.

 

This is particularly important if your parcel needs to remain within a courier's maximum external dimensions.

 

If you're unsure how to measure your product, read our How to Measure a Cardboard Box: Internal vs External Dimensions guide before ordering.

 

What Size Should I Make My Custom Box?
Start by measuring the maximum:

Length × Width × Depth

of your product.

 

Then consider how much additional room it needs for appropriate protection.

 

Don't automatically make the box exactly the same dimensions as the product.

 

Allow for manufacturing tolerances, ease of packing and any cushioning, wrapping, inserts or other protective materials the product requires.

The objective isn't to make the smallest box physically possible.

 

It's to create an appropriately sized box for the product and the protection it needs.

 

Single Wall or Double Wall Cardboard?
The correct cardboard grade depends on more than product weight.

 

You should also consider:

- Box dimensions
- Product shape
- Fragility
- Weight distribution
- Whether boxes will be stacked
- Storage conditions
- How the parcel will be transported

ASC Direct's Single Wall board is approximately 3mm B flute, while our Double Wall and Heavy Duty boards are approximately 6mm.

 

Single Wall can be suitable for many lightweight everyday products, while Double Wall provides additional rigidity for heavier, larger or more demanding applications.

 

Our Heavy Duty specification is designed for applications requiring greater board performance.

 

Read our Single Wall vs Double Wall Cardboard Boxes guide if you're unsure which to choose.

 

Which Custom Box Style Should I Choose?
The familiar FEFCO 0201 is one of the most commonly used cardboard box styles.

 

Its top and bottom flaps meet in the middle and are normally sealed using packaging tape.

 

But it isn't the only option.

 

ASC Direct's Box Builder includes different FEFCO styles suitable for different products and dimensions, including:

0200 – Open Top Box
A conventional carton construction without top flaps, useful for applications such as picking boxes and trays.

 

0201 – Standard Cardboard Box
The familiar regular slotted carton and a versatile option for a huge range of products.

 

0201 ALT – End Opening Box
An alternative orientation that can be particularly useful for certain long or narrow products.

 

0203 – Overlapping Flap Box
The top and bottom flaps fully overlap, providing additional reinforcement.

 

0400 / 0401 / 0409 – Wrap Boxes
Wrap-style packaging that can be useful for products such as books, frames, mirrors, flat products and other items where a conventional carton isn't necessarily the best solution.

 

Not sure what those numbers mean? Read our guide to FEFCO cardboard box styles.

 

Custom Shipping Boxes
A made-to-measure cardboard box can be particularly useful when products are regularly being sent through parcel networks.

Instead of choosing an oversized shipping box and filling the remaining space, you can manufacture packaging closer to the dimensions the product actually requires.

 

This doesn't eliminate the need for appropriate protective packaging.

 

But it can help reduce unnecessary empty space and void fill.

 

If you're designing boxes for a particular courier, remember that courier size limits usually relate to the finished external parcel dimensions, while ASC Direct's Box Builder asks you for internal dimensions.

 

Always allow for the thickness and construction of the finished cardboard box.

 

Custom Boxes for Small Businesses
You don't have to order thousands of boxes to use custom packaging.

 

ASC Direct manufactures custom-sized cardboard boxes from quantities as low as 25.

 

This makes custom boxes practical for:

- Small businesses
- Ecommerce sellers
- Etsy and marketplace sellers
- New product launches
- Seasonal products
- Subscription businesses
- Product testing
- Low-volume specialist products

Start with the quantity you actually need rather than committing to a large volume simply to access custom manufacturing.

 

Custom Printed Cardboard Boxes
Your shipping box doesn't necessarily have to be plain.

 

Printing can turn packaging you're already using into another part of your branding.

 

Depending on the Box Builder style and specification selected, printing options are available that allow you to add branding or designs to your custom boxes.

 

This means you can customise both:

The size of the box

and

The way the box looks.

 

For larger or more complex printing requirements, contact our team to discuss the available options.

 

Custom Boxes Without Waiting for a Quote
Traditional bespoke packaging often starts with an enquiry.

- You send your dimensions.

- Wait for a quotation.

- Discuss quantities.

- Then decide whether to proceed.

 

ASC Direct's Box Builder is designed to make buying custom cardboard boxes much simpler.

 

Enter your dimensions and specification online and see the price.

 

That makes it easy to experiment with different sizes, board grades and quantities before placing your order.

 

Measure it. Build it. Price it. Order it.

 

Frequently Asked Questions About Custom Cardboard Boxes
What are custom cardboard boxes?
Custom cardboard boxes are manufactured to dimensions selected for a particular product or application rather than being limited to predetermined stock sizes. With ASC Direct's Box Builder, you can enter the internal length, width and depth you require and receive an instant online price.

 

What is the minimum order for custom cardboard boxes?
ASC Direct's online Box Builder allows you to order custom-sized cardboard boxes from just 25 boxes.

 

Can I order one custom cardboard box?
Our online custom-box manufacturing starts from 25 boxes. This allows us to manufacture boxes to your chosen dimensions while keeping small production runs commercially practical.

 

Are custom cardboard box dimensions internal or external?
ASC Direct's Box Builder uses internal dimensions. The finished external dimensions will be larger because of the thickness and construction of the corrugated cardboard.

 

How do I measure for a custom cardboard box?
Measure the maximum length, width and depth of the product and then allow appropriate additional space for any protective packaging it requires. Enter the required finished internal box dimensions into the Box Builder.

 

Are custom cardboard boxes more expensive than stock boxes?
They can be. Stock boxes are manufactured in large volumes and can be extremely cost-effective. If a stock box fits your product properly, it may be the best option. Custom boxes become particularly useful when standard sizes leave significant unnecessary space or when your product has unusual dimensions. When comparing costs, consider the complete packaging process, including void fill, packing time and storage as well as the price of the box itself.

 

Can you make cardboard boxes to any size?
ASC Direct can manufacture a wide range of custom box dimensions, but manufacturing limits vary depending on the box style, board grade and dimensions required. Enter your dimensions into the Box Builder to see the options available, or contact us if you have an unusual requirement.

 

Can I get my logo printed on a custom cardboard box?
Yes. Printing is available for selected Box Builder specifications. Choose the relevant print option while building your box or contact us to discuss larger or more complex printed-box requirements.

 

What's the difference between Single Wall and Double Wall boxes?
Single Wall corrugated cardboard contains one fluted layer, while Double Wall contains two. Double Wall generally provides greater rigidity and strength, but it isn't necessary for every product. The appropriate choice depends on the product's weight, dimensions, fragility and journey.

 

What is a FEFCO 0201 box?
FEFCO 0201 is the familiar regular slotted cardboard carton. It has top and bottom flaps that meet in the middle and is one of the most widely used corrugated box styles for shipping, storage and ecommerce packaging.

 

Can custom boxes reduce void fill?
They can help. Manufacturing a box closer to the dimensions your product requires can reduce unnecessary empty space. Fragile products may still need cushioning and protective packaging, so the aim should be to remove unnecessary void rather than eliminate protection.

 

How quickly can I get custom cardboard boxes?
ASC Direct offers different production service levels depending on the box specification and how quickly you need your order. The available options and estimated dispatch date are displayed when configuring your box online.

 

Can I reorder the same custom box?
Yes. Save your Box Builder design to your ASC Direct account and give it a memorable name so that the same specification can be reordered without rebuilding it from scratch.

 

Build Your Custom Cardboard Box
If you've already measured your product, you're ready to get started.

Choose your box style.

Enter the internal dimensions.

Select your cardboard grade and quantity.

And see your price online.

Custom cardboard boxes manufactured to your dimensions – from just 25 boxes.