Tuck Boxes

A tuck box is the simplest folding carton structure: a single sheet of paperboard scored and die-cut into a tube shape with tuck flaps on the top and bottom. Both ends close by folding dust flaps inward and tucking the main flap into the box. Tuck boxes are the default format for playing cards, board game expansions, small toy sets, and single-item retail products like USB drives or phone accessories. The straightforward construction keeps die-cut costs low and makes hand assembly fast, typically 8-12 boxes per minute. The trade-off is that tuck flaps alone cannot hold heavy products because the base relies on friction rather than an interlocking mechanism. Weight capacity tops out around 8 oz before the bottom starts to give. Material options include 300-400gsm SBS for a clean printed surface, kraft for an eco-friendly look, and coated recycled board for cost-sensitive runs. Cubit produces custom tuck boxes from 100 units.