BOXSMITH Български

Guide · 15 minutes

How to make a box template that actually closes

Most free box templates are drawn for paper. Cut them from real card or corrugated board and the box closes a few millimetres short, the glue flap misses and the tucks jam. Here is how to get a template that fits on the first try.

Short answer: measure the inside size you need, measure your board thickness, and let every panel grow by that thickness. Then check the fold, confirm the file is at 1:1 scale, and cut with separate cut and crease lines.
BoxSmith studio: a reverse tuck end dieline next to the folded 3D box
The template (left) and the same box folded in 3D (right), in BoxSmith.

The 7 steps

  1. Choose the box style

    Box styles have standard codes from the FEFCO code, which print shops and converters understand:

    StyleBest for
    0215 Reverse tuck endCosmetics, perfume, bottles, candles
    0211 Straight tuck endPresentation and gift boxes
    0427 Roll-end tuck mailerE-commerce shipping and unboxing
    0501 Drawer & sleeveWatches, jewellery, premium gifts
    0201 Regular slotted containerShipping cartons

  2. Measure the inside size

    Measure your product's length, width and height, then add 1–2 mm of clearance to each so it slides in. These are the inner dimensions — the space inside the finished box.

  3. Enter the board thickness

    Every 90° fold uses up roughly one board thickness (τ). Measure your board with a caliper and enter it; typical values are 0.4 mm card, 0.6 mm luxury board, 1.5 mm E-flute and 2.8 mm B-flute. BoxSmith then applies the allowances for you:

    AllowanceValueWhy
    Panel growth+τthe box closes to its inner size
    Dust flap setback1.25τflaps clear the side walls
    Roll-over clearance2τdouble walls nest flat
    Glue flap taper15° + τno bulge at the top crease

  4. Check the fold in 3D

    Drag the fold slider from 0 % (flat sheet) to 100 % and rotate the box. You can see each flap close, spot a tuck that would hit something, and check where your logo lands on the front.

  5. Verify 1:1 scale before cutting

    Download the free 60×60×100 mm sample and open it in Illustrator, Inkscape or LightBurn: the front panel must measure exactly 60.4 mm (60 mm inside + 0.4 mm board). If you print the PDF, choose 100 % / Actual size and measure the 50 mm bar in the title block.

  6. Export and cut

    Laser cutter or Cricut: export SVG or DXF. Assign the CUT layer to a full cut and the CREASE layer to scoring or a low-power pass. Print shop: export the PDF; it includes the BLEED layer, so print colour runs past the cut line.

  7. Fold and glue

    Pre-fold along every crease first. Glue the side seam onto the glue flap, let it set, then close the tucks or flaps.

Dieline with cyan cut lines, red dashed crease lines and green bleed line
Cut (solid), crease (dashed) and bleed (dotted) on separate layers.
The folded box in 3D with a logo on the front panel
The same template folded, with the logo on the front.

Make yours now

BoxSmith runs in your browser and your files never leave your device. The studio and the test sample are free; unlimited SVG, DXF and PDF exports cost $3 once.

Open the BoxSmith studio →