Custom Oversize Boxes
When standard sheets aren't big enough, we engineer oversize packaging from scratch. Trade show displays, furniture, large equipment, and anything else the catalog doesn't cover - built in-house.
When to Use It
Common industries and use cases where this box type performs best.
Trade Show Displays
Large format display structures, booth backdrops, and pop-up stand packaging.
Furniture & Fixtures
Tables, shelving, lighting fixtures, and retail display cases shipped damage-free.
Industrial Equipment
Control panels, large motors, frames, and fabricated assemblies over standard dimensions.
Art & Framed Pieces
Custom-fit oversize boxes for canvases, framed artwork, mirrors, and large prints.
Board Grades
ECT (Edge Crush Test) measures stacking strength. Mullen measures burst resistance. Use ECT for palletized loads; Mullen for rough handling.
| Grade | Mullen Burst | Description | Best For | |
|---|---|---|---|---|
| 44 ECT | 200 lbs | Light oversize. Displays, soft goods. | Trade show materials, fabric displays | |
| 51 ECT | 275 lbs | Mid-range. Most oversize applications. | Furniture, fixtures, equipment | Most Common |
| 61 ECT (DW) | 350 lbs | Double wall for heavy oversize items. | Heavy machinery, dense equipment | Heavy Duty |
| Triple Wall | 500+ lbs | Maximum oversize structural performance. | Extreme loads, crate replacement | Industrial |
Flute Options
Flute profile determines thickness, stacking strength, and print quality. We stock all common flutes and produce custom combinations in-house.
C-Flute
Good for larger, lighter oversize items where print quality is secondary to coverage.
BC Double Wall
Best balance of rigidity and weight for most oversize applications. Resists flex on long panels.
AAA Triplewall
For the heaviest oversize loads where structural rigidity is the primary requirement.
Max Sizes We Produce
All sizes produced in-house on our own equipment - no outsourcing, no lead-time surprises.
CNC vs. Steel Rule Dies
For short runs and custom sizes, the difference is significant. Here's why our CNC-first approach wins.
✓ CNC Cutting (APG)
- CNC cutting handles oversize blanks that no die press can accommodate
- Irregular shapes, angled panels, and cutouts all cut in the same operation
- Large sheets are cut without repositioning - one-pass accuracy across 60"+ blanks
- No tooling means 5-unit prototypes are just as viable as 500-unit runs
- Internal component locating features, handles, and access holes cut simultaneously
✗ Steel Rule Dies
- No steel rule die press on the market handles 60"+ oversize corrugated blanks
- Large dies warp under press pressure, causing inaccuracy on wide panels
- Oversized jobs traditionally require hand-scoring and manual cutting - slow and imprecise
- Tooling cost for a large custom die can exceed $1,000–$2,000
- Any size change on an oversize box requires complete re-engineering of the die
Ready to Order?
From prototype to production - built in-house in Wylie, TX.