A six-sided box? Really? We have usually heard of the simple rectangular box with straight folds and predictable corners. Here the hexagon is the game changer. A box with the six panels that meet at the exact position and the lid on the top. The hexagon two-piece box is not so simple it looks elegant from every angle. It is the combination of structural design, material science, printing, and careful assembly.

“Good packaging is not only what you see. It is what makes the product feel right when you open it.”

For brands using distinctive packaging, that difference matters.

What Is a Custom Hexagon Two-Piece Box?

A two-piece box means two separate components: a base that carries the product and the lid that protects the product. Hexagonal structure means six sides of the box. The material of the box depends on the product, which may be the folding paperboard, thicker board, or rigid box. The shape of the custom boxes is designed around the product. This distinctive shape can create more visual attraction when there are so many other products around. But the challenge is that every panel of the box has to cooperate with others

Step 1: The Product Comes Before the Box

Before designing the box, the manufacturers have to get the answer to a few questions

• What are the product dimensions?

• Is the product fragile?

• How much distance does the product have to cover?

• The lid should slide easily ot need resistance when open

Here the simple rule is that the main priority of the box should be to protect the product inside, and second is to impress the customers. Just imagine if the box is oversized and the product moves inside the box it can damage both the product and the brand’s image.

Step 2: The Hexagon Is Converted Into a Structural Pattern

This box comes in a flat shape. The designer draws all parts of the box, means it sided, folding and cutting lines, and the areas where the box will be joined. Here, the main task is that all panels should be of the right size and placed at the correct angle. The lid should fit properly over the base. During designing sometime the box looks perfect on the computer, but it doesn't mean it will work properly in reality. Because in reality, the thickness of material used or even the direction in which the board will fold also makes a little difference. This is important because a hexagonal box has several panels that need to be folded properly.

Step 3: Choosing the Right Board

Material selection can be based on random choices, but it is selected according to the product inside. Means light material can work if the products are jewelry or sweets.

The choice depends on:

• Product weight and dimensions

• fragility

• Printing requirements

• Surface finish/coating

• Shipping conditions

• Interior inserts

• Desired unboxing experience

Step 4: Printing Comes Before Final Conversion

For premium packaging, the brands can't ignore the printing. Printing helps the boxes to communicate with the customers. Graphics, colors, texts, images, patterns, or information actually portray the personality of the product or the brand. Artwork of such boxes should be checked when the boxes have been assembled. 

Step 5: Die-Cutting Creates the Hexagon

Not done with all the selections related to material or printing; now the board is assembled to be the box that is required. For this, the brand needs die-cutting, which cuts the outline. Creasing and scoring also control folding lines. This is the most difficult but most needed. When we talk about the 6-dimensional box, it can change how the material behaves. Research into laminated paperboard has specifically examined cracking and delamination during creasing and folding.

Step 6: Finishing Turns Structure Into a Brand Experience

For the box, the designer can choose any finishing options. Packaging company EZ Custom Boxes provides them with so many choices so that they can select according to their product.

• Matte or gloss lamination: gives a premium touch 

• Soft-touch coating: gives the tactile experience

• Foil stamping: portrays the luxury appearance

• Embossing or debossing: makes the logo noticeable

• Spot UV: provides external protection

• Printed interior surfaces: provides more space to write

• Ribbons or decorative elements: make the product look exclusive

If the brands want to select the finishing option, then it should be according to the product.

Common Mistakes to Avoid

A few seemingly small decisions can undermine an otherwise beautiful box:

• Ignoring material thickness: 

• Designing only in 2D: 

• Using excessive finishing: 

• Skipping physical prototypes: 

• Choosing appearance over protection:

Create a Hexagonal Package Designed Around Your Product

The custom hexagonal two-piece boxes are more noticeable, as sometimes the box that looks different becomes more memorable. EZ Custom Boxes is here to help the brand design customized boxes with the goal of making the box look completely different. This unusual packaging can make the unusual packaging into memorable packaging

Contact EZ Custom Boxes:

Email: [email protected]