Custom Packaging Size and Structure Development
When a standard size or format does not fit your product, send us your technical brief. We will review the fit, dimensions, opening and inserts your packaging needs, and agree the scope with you before work starts.
Example drawing only, not a production dieline.
Supported Packaging Formats
Mylar bags and pouches
Stand-up and flat pouches in custom sizes, with zipper or heat seal closures.
Mailers
Poly, bubble and padded mailers in custom sizes, depending on the product and order.
Mailer boxes
Foldable and rigid mailer boxes in fully custom sizes, with inserts where needed.
Structural Requirements We Address
Fit
How your product sits in the pack, including any room it needs around it.
Dimensions
The width, height and depth or gusset that suit your product and fill amount.
Opening and closure
Zipper, heat seal, tuck end, self-lock, magnetic or sleeve, depending on the format.
Inserts
Foam inserts or cardboard dividers for boxes, cut to hold your product in place.
Technical Inputs Required
The more of this you can send, the easier it is to review your project. If you are missing pieces, send what you have.
- Product dimensionsLength, width and height of the product or set
- Product weightAnd whether it is fragile, dry or has a strong scent
- Preferred formatPouch, mailer or box, or tell us if you are unsure
- Opening and closureHow the customer should open and reclose it
- Reference filesSketches, photos, an existing dieline or a pack you like
- Quantity and deadlineHow many you need, and when
Development Process
- 1
Technical brief
Send your product details and what the packaging needs to do.
- 2
Scope review
We review whether it can be made, and confirm the scope and any cost with you.
- 3
Structure and review
We prepare the agreed structure, and you review it and ask for changes.
- 4
Approval
You approve the structure before it moves to artwork or production.
What You Receive
What you receive is agreed with you when we confirm your project scope.
- Agreed dimensionsThe final sizes for your packaging
- Structural dielineThe template used for your artwork and production
- SpecificationsFormat, material, closure and any inserts
Prototype and Review Stages
Digital proof
Shows your size, artwork placement and finish, and you can ask for changes before approving it.
3D sample
Lets you check the pack on screen from every angle before anything is printed.
Physical sample
Lets you test the fit, material and closure with your own product. We confirm its cost first. More about samples
A Box Built Around the Product
Tap a pin to follow this concept from requirement to result.
Requirement
A small set needs a box that holds each piece apart in transit.
Structure
A rigid box is sized to the set, with dividers cut to fit each piece.
Review
A physical sample is checked with the real product before approval.
Costs, Revisions and Lead Times
Confirmed first
Costs depend on the structure and format. We confirm them with you before work starts.
Agreed in scope
We agree how changes are handled when we confirm your project scope.
Given with scope
Timing depends on the structure and sample stages, so we give it when your scope is confirmed.
Not every structure
If we cannot make what you need, we will tell you plainly. We do not offer certification or lab testing through this service.
Technical FAQs
When do I need this service?
When a standard format or size does not suit your product. If you only need help choosing from existing options, start with Packaging Consultation.
Can you use my existing dieline?
Send it with your brief, and we will review it with your other requirements.
Which files should I send?
Send sketches, photos or dielines in the format you have. For artwork, vector files such as AI, EPS or PDF are best.
Can I test the structure before ordering?
Yes. You can ask for a physical sample, and we confirm its cost with you before it is made.
Do you certify packaging performance?
No. Test the packaging with your product, and confirm any rules that apply in your market.
Submit a Technical Brief
Tell us your product, its dimensions, the format you want and what the structure needs to do. You can attach a file too.
