Design of Two Main Forming Methods
Tube-Style Forming
The outer sleeve is formed from a single sheet of paperboard with a designated glue flap on the side; it is assembled by folding and gluing the flaps. While the basic shape is rectangular, it can be adapted into polygonal forms. It can incorporate locking mechanisms-such as tuck-in flaps-resulting in a refined appearance suitable for gift packaging.
Tray-Style Forming
Centered on the base panel, the surrounding paperboard walls are assembled via interlocking tabs, slots, or spot-gluing, eliminating the need for extensive adhesive application. The resulting sleeve has a low profile and a large internal display area, making it ideal for accommodating larger inner boxes.
Structural Fit Design
Determine dimensions based on the inner box using the following formula: Outer Sleeve Length (L+) = Inner Box Length (L) + Chipboard Thickness (a) + 2 × Facing Paper Thickness (t) + 1mm. Apply similar tolerance allowances to the width and height to prevent the box from sticking or sliding out loosely during use. V-grooving can be employed to reinforce the corners and enhance the overall rigidity of the outer sleeve.
