Rigid Box Making Process 精装盒子制作过程

 Rigid Box = 湿裱盒 / 精装盒 / 湿糊盒 / 硬盒

由灰纸板与表面裱纸黏贴组合。具有坚硬，结构不变形，高档精美的特点，常用于礼品，高端电子产品，珠宝等产品的包装。这种包装盒因其强度高且呈现出高品质的视觉效果，成为提升品牌形象的常见选择。

Rigid box is a very common type of packaging carton.

Rigid box is often used for luxury products packaging.

Rigid box is typically thicker, prettier and stronger than as average folding carton.

Rigid box is instead made of 2-3mm thick greyboard or chipboard inside, wrapped with art paper that can be as plain or luxurious as desired.

The Process to Make a Rigid Box

1. Grooving or slotting chipboard for sharp folds
2. Corner Tape 灰板打角
3. Positioning the board onto glued wrap paper 面纸过胶定位
4. Forming (to wrap the paper and finish the box structure accurately)包盒
5. Bubble Press 压泡
6. Inspection 检查
7. Assembly 组装
8. Packing 包装

Manufacturing rigid boxes involves several key steps: processing the chipboard (cutting, grooving), preparing the cover paper (gluing), precisely positioning the board onto the glued paper, and automatically wrapping and folding using a dedicated rigid box making line.

While the inner greyboard or chipboard is the skeleton (framework). It is 2-3mm in thickness, which makes the box very rigid and strong. Cutting dies are used to cut the chipboard to its custom size and shape, while scoring dies are used to crease the grey board for the folding and set up of the of the rigid box.

The foundation of a rigid box is its structure, typically made from chipboard. First, large sheets of chipboard are cut down to the specific flat size needed for the box base and lid. This is done using a die cut machine. After cutting, the board needs processing to allow for clean folds. Here, you have a key choice: half cut or v-cut.

Half cut, often used with die cut machine, half cutting into chipboard where fold are needed. This can sometimes leave slight recesses that might show through the wrap paper. Grooving, however, cut V-shaped channel into the board where folds are needed. This allows the board to fold into perfectly sharp, 90-degree angles without removing corner material, leading to a much cleaner, more premium look with "pretty plump right angles".

While the chipboard is prepared, the outer wrap material (printed paper) is prepared separately.

The outer wrap is the skin of the paper box, which is beautifully decorated. It has the very fine finish and printing, very eye-appealing.

As illustrated below, the 4 side panels of the box are folded up along the scoring lines to form the framework.

Next, tape is applied to secure the sides using a machine called a quad stayer.

These processes are done by the machine.

 

The wrap is the outer skin of the rigid box,. Wrapper has very fine printing, texture and finish, giving a luxury feel. Wrapper is well prepared and trimmed perfectly to fit the box. The wrap paper is fed into the gluing machine. The gluing machine applies a precise layer of glue evenly across the surface. Getting the glue consistency and amount right is important for a good bond without seepage. The skeleton formed by the chipboard is then accurately placed on the wrap where glue is used to adhere the chipboard and wrapper together.

Box Forming & Finishing is where the box takes its three-dimensional shape. The glued wrap with the positioned chipboard is move to rigid box forming machine or manual jig. Then, fold the wrap edges up and over the chipboard sides. The corners are carefully tucked and folded. After that, fold the turnover edges inside the box for a neat finish. 

Bubble press is applied to ensure the wrap adheres smoothly and securely to the board structure. 

The completed box base or lid is then ejected onto a conveyor belt, ready for assembly (if it's a two-piece box) or further processing like adding inserts.

Type of Rigid Box:

• Rigid box with lid and base: Most rigid boxes consist of basically two parts - a lid on the top; and a base at the bottom

Rigid box with lid and base

• Hinged Lids Rigid Box: Unlike the lift off lid rigid box, the hinged lids rigid box is a one-piece package. The lid is attached permanently to the bottom base. The lip can flip open easily like a book or a clamshell. Therefore, it is also called flip top box, cigar box or clamshell rigid box. There are many different style of hinged lid rigid boxes. 

Hinged Lids Rigid Box

• Slide Rigid Box with ribbon pull tab

Slide Rigid Box with ribbon pull tab

• Collapsible Rigid Box or Foldable Rigid Box: Rigid box can be took into consideration to replace a folding carton, or printed paper box when protection and durability during transport and often rough retail environment are major factors. In addition, in the consumer's home, where repeated use and storage of the product in the box is an asset, rigid boxes will add value for customers.

Foldable rigid box

• Custom Rigid Box

Custom rigid box

• Neck Box or Shoulder Box: An extra tray is glued on the side panels of the base and protrudes up past the top edge of the base. This protrusion creates a "neck" and the top edge of the base becomes the "shoulder". Such a rigid box looks quite elegant.

• Sometimes the "neck" is made extra long and it protrudes past the lip of the base so much so that it creates a gap between the lid and the base. This is done mostly for esthetic reasons.

Manual folding can vary.

Automated grooving and forming ensure perfect, sharp edges every time, giving packaging a high-end feel.

Reference:

• https://www.deprintedbox.com/blog/how-does-our-factory-make-the-rigid-paper-box/
• https://kylinmachines.com/how-to-make-rigid-boxes-efficiently-using-machines/