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How to Make a Custom Box for Shipping

by James
shipping boxes

It can be challenging to find the right box size for your shipping needs and shipping costs can quickly add up. We’re going to show you how to avoid these frustrations and make your own shipping box in this post so stick with this post.

Things you’ll need to Create a Custom Box for Product Shipping:

Square or rectangular box of your desired size. Heavy duty packing tape, or Duck Tape if you prefer. 2 x Wooden Dowels or 3/4” PVC pipe(s). This will serve as the skeleton for the box. The thicker these are, the sturdier your shipping box will be. Cutting Knife to cut the dowels to length (optional). Ruler Scissors (better option than a knife) Fine-Point Permanent Marker A container of water to put the dowels in when cutting them to length (prevents accidents from dull cutting knives).

Here are Some Steps Which you Can Follow to Create a Custom Box for Shipping

Step 1: Cut the Dowels in your First Step

Cut the Dowels to Length. If you are using PVC pipe, cut them down to length using a PVC cutting knife. Otherwise, use a ruler and a fine-point permanent marker to measure the length of your dowels and draw parallel lines on both sides for the dowels to sit in. Mark 48” (or whatever length you want) from each end. 

Step 2: Measure the Box Properly and Resize them

Measure the Interior of Your Custom Box.  I chose 38 ½” from the bottom of my box as it is about average for most books and other packages I send out in my email blasts. Cut two 48” dowels from your PVC pipe.

Step 3: Box Container to Make them Durable

Prepare the Box. Wet the bottom of your box with a container of water (4 cups for a typical shipping custom box, or 1 cup for small boxes) so that you can avoid dull knives. This will make it easier to cut through the cardboard and keep your fingers away from slipping while cutting the dowels to length.

Related Post: Cartridge Boxes for Brand Packaging

Step 4: Now Dry Your Dowels Properly

Move to your cutting area and set up one dowel at the bottom right corner of your box as shown in this picture; then, stand it upright against where you want it to end up (see Step 5). I had the book to the left of the dowel, so I set my book up against that side.

Step 5: Place the Dowl in its Right Position

Place the Next Dowl . Move your dowel over to where you want it to go and place it as shown in this next photo as you hold it upright against your box, then continue placing your dowels into place until your entire structure is complete (see Step 6). I placed about two-thirds of my box’s surface with this first stand of dowels.

Step 6: Add One More Dowl for Double Protection

Stand another dowel up against each of its neighbors at either end. I placed another two-thirds of my box’s surface this time, but the exact number of dowels you place will depend on the size of your box.

Step 7: Cover the Box Properly with Tape

Cover the Box with Tape. Once your structure is complete, cover your box in heavy duty duct tape to secure it and prevent any movement of your shipping box (see Step 8). I used about 6 layers for my shipping box. You can use less if you want a lighter weight box or more if you want a heavier weight product to ship.

Step 8: Cover the ‘Joints’.

Cover the joints with tape to prevent bending and slippage of your box while in transit (see Step 9).

Step 9: Put your Product Properly:

Put Your Contents inside Your Box. Fill your shipping box with your intended contents. Then, add several layers of tape over the top seam and right down on top of your book, so it is securely in place (see Step 10). This will help keep everything secure during transit.Finish by tapping the bottom edge of the box, while holding up its opposite side to allow gravity to create a nice taper (see Step 11). When you are done, your shipping box should look like this (see Step 12).

Step 10: Make them Ready for Shipping:

Give Your Box It’s Final Look. Once your box is finished, give it a final look by removing all of your tape with a sharp knife (or scissors) and apply a label to the front with your intended shipping address and the product’s weight. If you decide to use Duck Tape for this, remember to cover the part of the tape that covers the seam of your wood dowels so you don’t have to open up later.

Step 11: Don’t Forget to Consider UPS for Reliable Delivery:

Put It All Away. Move this step to after your shipment is complete and put everything away as you normally would before sending out items through USPS or UPS. I’ve used these shipping boxes for years now and find them to be quite sturdy. You could use other packaging materials, such as bubble wrap or styrofoam peanuts to help provide extra padding and protection against shock.

You must have to Ensure that the custom box is safe for shipping to pack your items properly and maximizing the life of the product (and also, if you think about it, it just makes sense!).

I hope this post helps you save some money on shipping costs while increasing the quality of your product(s) in transit!

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