How Do You Make a Cardboard Box?

The humble cardboard box is the answer to many postal and storage solutions.

Millions of cardboard boxes are produced and used worldwide every day.

 Many are used for business purposes, but creating a custom-made box for a Christmas gift or to store precious letters or mementoes can be a fun project’

Making your own box using recycled material is a great way to tailor your package to its contents.

We hope you find the ideas in this blog helpful.

Sourcing your material

The first step is to find high-quality cardboard for your box. Using second-hand cardboard is a good way to create sustainable packaging. Cardboard can be found everywhere in the home.

You could give an old cardboard box a second life if it provides enough material for the new box you require. You will need to remove any old tape from the first box before you start.

Thicker corrugated cardboard, like that used in large appliance packaging, is tougher and will make a more durable box for storing or shipping both fragile and heavy items.

Light cardboard, such as cereal boxes or shirt packaging, is useful for small boxes that are mainly for decoration or for storing small items.

How to construct a cardboard box

A cardboard box can be constructed from a piece of cardboard by cleverly folding it into a cube. It is easy to create a custom cardboard box, even without a template, if you know the dimensions you need.

The stages of making a box are as follows:

• Find a long straight piece of cardboard and lay it flat on the floor.
• Measure the cardboard to ensure it will make the size of cardboard box you require.
• Use a ruler to measure four equal sections on the cardboard
• Using a sharp knife or box cutter, score the edge of each section without cutting through the cardboard.
• Fold along the cut lines to form a cube.
• Place your item inside the box, then tape the sides and top flaps to seal the box.

Making a simple box is straightforward, but making one sturdy enough to be sent in the post or used for long-term storage requires a little more planning.

Building cardboard boxes that protect their contents

If you follow the instructions above, you will create a box, but you may need to put a bit more effort into ensuring it protects its contents well.

You can keep even the most fragile contents safe by using tough materials and packing them correctly.

Use corrugated cardboard to construct your box

Thick or corrugated cardboard is tougher than lighter cardboard and is essential for protecting goods in transit or for heavy items in storage. A corrugated cardboard box will protect its contents from damp and from accidental impact.

Stabilise contents with bubble wrapping

Pushing bubble wrap into the empty corners of your box will prevent the contents from shifting and sustaining impact damage.

Pack your box so that it remains upright

If you need to keep your box upright, you should stabilise the contents with bubble wrap and shredded paper, then put a sign saying”this way up” on the outside of the box.

Choose the right size of box

Always choose the right-sized box for the contents. A small box may not provide enough protection, while the contents may rattle around and get damaged in a box that is too big.

Secure your box with tape

We sometimes see boxes glued together, but this is not advisable unless it is a small decorative box. We recommend a double-sided tape to secure the edges and corners of your box, as it gives a smooth finish and is more durable.

More information on making a cardboard box

If you would like more ideas, you can find plenty of videos online and on platforms like Pinterest with instructions for making all kinds of cardboard boxes.

Pacsafe Cardboard Boxes

If you need multiple boxes or want to ensure your box is tough and durable, browse our selection of cardboard boxes.

Boxes are our business, and we provide a variety of types and sizes for all purposes. You can browse our range of cardboard boxes here.