Custom Pillow Boxes

How a pillow box gets its curve

One cut sheet bends into a curved tube and locks at the ends, with no glue.

The blank has curved fold lines along the sides and a tab and slot at each end. The two long edges are brought together so the sheet bows into a pillow shape, and the ends close with a tuck or interlock. Nothing is stuck.

Because it ships flat and assembles in seconds, a pillow box takes little room to store and little time to pack. The curve is what holds the shape: the bowed walls press against each other and keep the box closed.

• Curved fold lines, no glue
• Tab and slot ends
• Ships flat, assembles in seconds

SBS, kraft or textured paper?

Thin, flexible stock bends into the curve. Thick or brittle stock fights it.

SBS paperboard is smooth, folds cleanly and prints sharply, so it suits bright artwork. Recycled kraft gives a natural look and bends easily, but colours print darker. Textured papers feel good in the hand and can crack at the fold if they are too stiff or too dry.

Board caliper matters more here than in most cartons. Heavy board will not hold a smooth curve and tends to kink along the fold. If the box needs to carry more, a smaller pack is usually a better answer than a thicker board.

• SBS: sharp print, clean fold
• Kraft: natural, darker colour
• Textured: tactile, check it for cracking

Sizing a curved box

The curve cuts into the space inside, so the usable room is less than the length and width suggest.

The ends of a pillow box curve inward, which means a rectangular item loses its corners to the bend. Round, soft and flat items fit best: bracelets, hair ties, wrapped sweets, gift cards. Hard square items sit awkwardly.

Measure the item at its thickest point and make sure it clears the crown of the curve. A product that presses on the walls forces the box open at the ends. Send us the item's measurements and we draw the box around them, so you can check the fit on the dieline and digital proof.

Pillow box or tuck-end carton?

A pillow box is quicker and gentler on the contents. A tuck-end carton is stronger and stacks.

A tuck-end carton has flat sides and square corners, so it uses a rectangular space well and stacks on a shelf. It needs a glued seam.

A pillow box skips the glue and gives a soft, gift-like shape, but it does not stack well and holds less. It suits small items sold singly or handed out, where looks and speed matter more than packing density.

Print, hang holes and the curve

Artwork is printed flat and then bent, so the curve distorts anything that runs across it.

A pattern that crosses the bend stretches slightly, and a border line near the fold can look uneven. Centre the key artwork on the flat part and let the sides carry colour or texture. Heavy coatings and foil can crack on a tight curve, so we keep them to the flatter panels.

A hang hole is cut in the same pass as the shape, so it can turn a pillow box into a retail pack for a peg or hook. A window cut-out is also possible, though a large opening weakens the curve.

• Keep key artwork on the flat area
• Foil and heavy coatings crack on a tight curve
• Hang hole cut with the shape

Pillow box, or a mailer for the post?

A pillow box is the pick for light items handed over or sold singly. A mailer box is the pick for anything posted on its own.

Pillow boxes offer little protection against crushing or heavy contents. Heavy or sharp items force the curved walls open or push through the ends, and the box cannot stand a drop or a squeeze, so fragile goods sent in the post travel in a mailer box, with the pillow box inside if you want the reveal.

The closure is also not sealed. Loose food, items that must be tamper-evident and anything that needs to stay put should go in a stronger style with a firmer lock.