Double Wall Box
Double-wall corrugated boxes with two flute layers for heavy, fragile or high-value shipments — the extra board takes more stack weight and impact so your product arrives intact. Custom size, grade and print for industrial and premium freight.
At-a-glance specs
- Structure
- Double-wall (2 flute layers), RSC or die-cut
- Board grade
- B-flute · E-flute · EB-flute · Kraft
- Thickness
- 1.5 – 3.0 mm (32 – 44 ECT)
- CMYK + Pantone, inside & outside
- Finishes
- Matte / gloss / soft-touch / foil / spot UV
- MOQ
- 500 units (sample: 1)
- Lead time
- 8 – 12 business days + shipping
When one layer is not enough
Twice the wall
Two flutes stack more weight and spread impact better than single-wall.
Fragile-safe
Extra cushioning for glass, electronics and machinery parts.
Pallet-grade
Holds up under stacked freight and long transit.
Still printable
CMYK + Pantone outside, plain or branded inside.
What is a double-wall box?
- (‘Two flutes — roughly double the stiffness of single-wall.’, ‘Stack-tough — holds weight lower in a pallet.’, ‘Impact buffer — more board between product and shock.’, ‘Brandable — printed outside, clean inside.’)
Specifications
| Structure | Double-wall — two flutes, EB or BC grade |
|---|---|
| Board grade | B-flute · E-flute · EB-flute, tuned to product weight |
| Material | Kraft · White-top Kraft · 100% recycled corrugated |
| Printing | Offset CMYK + Pantone · HD digital · full-bleed |
| Finishes | Gloss / matte / soft-touch lamination · foil · emboss · spot UV · window |
| MOQ | 500 units — price breaks at 1k / 5k / 10k+ |
| Turnaround | 8–12 business days after approval · rush available |
| Free with quote | Custom dieline + physical sample or 3D mockup |
Corrugated board thickness
The flute is the wavy layer between the liners — it decides how thick, stiff and protective your box is.
Frequently asked questions
When do I need double wall? +
Which grade — EB or BC? +
Can it print? +
What is the MOQ? +
How fast can I get them? +
Our Ordering Process
Four simple steps from first inquiry to boxes at your door.
Send inquiry
Tell us size, qty, material & artwork. Get a firm quote + free dieline in 24h.
Proof & sample
We send a digital proof or physical sample for your sign-off before production.
Production
Printed and finished in 8–12 business days with rigorous quality checks.
Delivery
Flat-packed and shipped worldwide, with tracking and after-sales support.
What brands say about our double-wall boxes
Industrial and fragile-goods shippers rely on the extra wall to cut damage claims and returns.
“PackagingSmith nailed our corrugated boxes on the first proof. The print quality beats our old supplier and the dieline was free — exactly what a growing brand needs.”
“We reordered four times in six months. The board feels solid in hand and the closures stay tight every time. Customers think the box costs more than it does.”
“Switched from a local printer and saved around 22% on landed cost. The free dieline caught a structural issue before we hit tooling. Worth it on the first run alone.”
Survives the stack
The second flute took our returns from noticeable to near zero on palletized freight.
See options → Glass and electronics
Extra board between product and shock means delicate items arrive intact.
Start customizing →Brand stays consistent
We keep the same outside print as our single-wall line, so the program looks unified.
See options → Customers also bought
Complete the unboxing — most orders ship together with these add-ons.
Custom Tissue Paper
Branded inner wrap that turns delivery into an unboxing moment.
View tissue →
Stickers & Labels
Seal tissue, brand the closure or add a thank-you touch.
View stickers →
Pillow Boxes
Light inner packaging for accessories and small gifts.
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Rigid Drawer Boxes
Premium inner box that ships safely inside your carton.
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