Rigid Box Template with Wraps and Greyboard

A rigid box, also called a setup box, is greyboard 1.5 to 3 mm thick covered in printed paper. It arrives built, never flat, and it does not fold away, which is why it feels solid in the hand. A rigid box dieline is the plan of the printed paper, the wrap; a rigid box template also needs the greyboard pieces under it and the liners inside.

This rigid box template draws all three from the size of what goes inside. The wraps carry the cut line, the folds at every board edge, the bleed and a safe area for the design; the liners are plain panels a little smaller than each floor; and the greyboard sheet gives each piece to cut.

Start from the product: measure its length, width and height and add a few millimeters if it sits in an insert. Those are the inside sizes. The template adds the board, so a gift box 8 × 6 × 3 in inside on 2 mm greyboard is 8.39 × 6.39 × 3.16 in outside with its lid on.

The wrap sheets grow faster than the box: each wall, its top strip and its turn-in lie flat around the bottom. The table gives each ready size’s outside, its board and its largest wrap, the number your box maker checks against a press sheet.

The lid is a second tray, built over the base: its inside is the base’s outside plus 1 mm each side, enough to slide on and stay on. By default the lid is as deep as the base, a full lid that covers the walls to the table.

Set a lower lid depth for a shoulder of base wall below it, a common look for gift and apparel boxes; 15 mm or more keeps the lid on, and the Checks tab says when a lid is shallower.

A magnetic book box opens like a book. Its case is one wrap around four boards: the bottom the tray is glued to, the spine behind it, the cover over the top and the front flap that comes down over the tray’s front. The magnetic box template leaves a hinge gap of one board plus 1 mm between each pair, so the cover bends and closes flat.

The case boards reach 2 mm past the tray at the sides and the front, so the cover frames the tray. Two round magnets, 10 mm across to start, are marked on the flap board; their pair goes in the tray’s front wall, set flush before the board is wrapped.

The turn-in is the paper that folds over an edge onto the inside of the board, 15 to 20 mm in most rigid boxes. The template starts at 18 mm, which holds well on 2 mm greyboard and stays under the liner.

On the tray wraps the turn-ins stop 0.5 mm short of each inside corner and the long walls’ ears wrap round the corners first, so the end walls cover them. On the case the corners are cut at 45 degrees, and the paper left past each board corner folds over it before the two turn-ins.

Greyboard for rigid boxes runs from 1.5 to 3 mm. 2 mm suits most gift and cosmetic boxes and is where the rigid box template starts; past 300 mm a side, about 12 in, the box starts on 2.5 mm so the walls and the cover stay flat. 3 mm is for heavy contents such as bottles or electronics.

Board thickness is built into every number: the trays, the lid’s fit, the case boards, the spine and the hinge gaps all follow the board you pick, and the inside stays the size you typed.

Box makers ask for one file per printed sheet. Download the wraps as a production PDF: the box at actual size with a 3 mm bleed following every cut, a 4 mm safe area, cut and fold lines as spot colors set to overprint on their own layers, and a notes page with every size. Download the liners the same way, and the boards as a sheet with no bleed.

Every face of a wrap is named on the rigid box dieline, and text you place in the Design section is turned to read upright on the built box, the detail printers most often ask about. Box makers each have their own turn-in and fit, so send the numbers you used and match them to theirs.

After a download, Design this box with AI opens AI gift box design with the whole rigid box: it designs the main face first, the lid’s top or the book box’s cover and flap, then the other faces to match, laid on the wraps with the turn-ins in the background color.

You pay only for the designs you receive. For a name or a logo on the lid, the Design section adds it right on this box; open the dieline generator for the other box styles, or all box templates for printable boxes.