How to make a package delivery box?

Sending packages in the mail or through delivery services like UPS and FedEx often requires properly packaging your items to ensure they arrive at their destination undamaged. While you can buy pre-made boxes and padding materials, making your own custom package delivery boxes can be easy, affordable and eco-friendly.

What Do You Need for a Package Delivery Box?

The supplies needed to make a package delivery box include:

• Cardboard or cardstock for the walls of the box
• Tape or glue to assemble the box
• Padding material like bubble wrap, newspaper or packing peanuts to protect box contents
• A box cutter, scissors or craft knife to cut the cardboard
• A ruler or measuring tape to measure the box dimensions
• A pen or pencil to mark cutting lines

Choosing the right cardboard thickness and padding materials depends on the weight and fragility of the items you’re shipping. Heavier items require thicker, stronger cardboard so the walls don’t collapse. Fragile items need more protective padding to prevent breaks and damage during transit.

How Big Should Your Package Delivery Box Be?

Determine how big your package delivery box needs to be based on the size and shape of the item(s) you need to ship. It’s important to accurately measure the contents first so you can design a properly fitted box.

Here are some tips for measuring box dimensions:

• Measure the length, width and height of the item(s) with a ruler or measuring tape.
• Add 2-3 inches of padding clearance around the contents for bubble wrap or other protective padding.
• For multiple small items, measure the combined width, length and height needed to fit them all.
• Err on the larger side – it’s better to have a box slightly too big rather than too small.
• Keep weight limits in mind for carriers like USPS or UPS if applicable.

Customizing the box size to fit your items helps minimize extra empty space inside. This prevents contents from shifting and cushioning materials from settling during transit.

How to Cut Cardboard for a Package Delivery Box

Once you know the size you need, it’s time to cut the cardboard pieces that will form the walls of the box. You’ll need to cut the following:

• Bottom – Cut 1 piece the length and width of your measured dimensions.
• Sides – Cut 4 pieces to the height of your dimensions, and the length or width. (2 matching pieces for the length sides, and 2 matching pieces for the width sides.)
• Flaps – Cut 4 small flaps that will fold inward to assemble the walls.

Follow these steps to measure and cut your cardboard:

1. Use a ruler and pencil to carefully measure and mark cutting lines on your cardboard according to your box dimensions.
2. Set your box cutter blade depth to just slightly deeper than the thickness of the cardboard.
3. Align the box cutter along the edge of a ruler on your marked cutting line.
4. Apply firm, even pressure and drag the box cutter down the line to slice through the cardboard.
5. Repeat for all measured dimensions so you have all cardboard pieces cut out.

Avoid forcing the blade while cutting to prevent jagged edges. Change the box cutter blade if it becomes dull.

How to Assemble the Cardboard Box Pieces

Once your cardboard pieces are cut, it’s time to assemble them into a box. Follow these instructions:

1. Apply tape or glue on the tabs of the side pieces.
2. Attach the tabs to the edges of the bottom piece so the sides stand up vertically.
3. Add tape or glue to the flaps and attach them just inside the corners for reinforcement.
4. Ensure the sides are tightly aligned at the corners and press firmly so the tape/glue sets.
5. Place any fragile contents inside and add padding material around them for cushioning.
6. Before sealing the box, test its strength by gently pressing on the walls and bottom.
7. Tape the top flaps closed securely using shipping tape. Reinforce the seams with additional tape if needed.

Your custom cardboard package delivery box is now ready for shipping! Make sure to clearly label with the delivery address, postage, fragile warnings or any other markings required by your carrier.

How to Make Your Package Delivery Box Stronger

For valuable or very fragile items, follow these tips to further reinforce and strengthen your custom cardboard shipping box:

• Use thicker cardboard – Upgrade to a heavier cardstock thickness better suited for heavier contents.
• Double up cardboard layers – Add an extra bottom layer and use 2-walled side pieces for added stacking strength.
• Add metal staples – Staple the seam joints versus just taping for a more secure hold.
• Wrap corners in tape – Criss-cross clear packing tape over the interior and exterior corners to help them withstand impacts.
• Line with bubble wrap – Covering the bottom and sides with a layer of bubble wrap cushions from all angles.

How to Save Money Making Your Own Boxes

Constructing your own custom cardboard shipping boxes can help you save money compared to buying pre-made boxes and packaging supplies. Here are some money-saving tips:

• Check for coupons and shop sales when purchasing cardboard sheets and other supplies.
• Use lighter cardboard for smaller, lighter packages to avoid overspending on materials.
• Buy cardstock in bulk rolls rather than smaller sheets to get bulk discount pricing.
• Save and reuse any undamaged cardboard scraps for smaller boxes.
• Use eco-friendly, inexpensive padding like newspaper instead of pricing bubble wrap.
• Reuse old boxes and padding materials from shipments you receive.

With some creative cost-cutting and resourceful recycling, you can make high-quality, customized delivery boxes on a budget.

How to Make Your Package Delivery Box Eco-Friendly

Upcycling cardboard and other packaging supplies is a great way to reduce waste being sent to landfills. Here are some tips for eco-friendly shipping box construction:

• Use only recycled content cardboard and paper padding fillers.
• Print any labels/markings with soy-based inks.
• Avoid plastic bubble wrap and foam peanuts which are not biodegradable.
• Compost any natural padding materials like paper after use.
• Reuse all undamaged boxes and materials to make new boxes.
• Offer used boxes locally through Buy Nothing groups or social media.

When sourcing, building and shipping your packages sustainably, you can feel good about using a custom made box.

Creative Ways to Decorate Your Package Delivery Box

Beyond just getting your package securely from point A to point B, you can also have fun decorating your handmade cardboard shipping boxes with any of these creative ideas:

• Use colored tape, markers or paint pens to add patterns, designs or writing.
• Stencil or stamp shapes, letters or images with craft supplies.
• Attach photos, magazine cut-outs or digital printouts with a theme.
• Add dimensional accents with yarn, pom poms, fabric scraps or foil shapes.
• Incorporate gift wrapping supplies like ribbon, bows or tissue paper.
• Reuse wrapping paper to cover the box sides or lid.

Personalizing your packages with DIY decorations can make the unboxing experience more fun and memorable for recipients.

How to Ship Packages in Your Handmade Boxes

Once your custom package box is assembled, padded, sealed and decorated, you’ll need to prepare it for carrier shipping and handle any required paperwork or postage.

• Weigh your box and contents on a mail scale. This verifies it meets the carrier’s weight limits.
• Measure dimensions and input details if shipping online for a rate quote.
• Add proper shipping address, return address, and other variable markings.
• Affix appropriate postage if not purchasing online.
• Include any special handling or mailing instructions like “Fragile”.
• Print shipping labels and tape securely to box exterior.
• Drop off at your carrier’s drop box or schedule a parcel pickup.

With the rise in online shopping, shipping custom packages yourself can save time and money over paying retail rates at the post office.

Conclusion

With just some simple tools, supplies and techniques, you can easily create custom, reusable shipping boxes perfect for all your delivery needs. Personalizing your packaging adds a special homemade touch while also allowing you to save money and reduce waste.

Follow the measurement, construction, decoration and shipping tips outlined above and you’ll have durable, eco-friendly and creatively designed boxes ready for all your postal and delivery service packages. The versatility of cardstock also lets you customize sizes and features to properly fit and protect a wide variety of contents.

Empower yourself by making deliveries more convenient on your own terms with handcrafted, precisely sized cardboard boxes. You can accommodate everything from gifts and online orders, to fragile valuables and holiday care packages. With the satisfaction of do-it-yourself resourcefulness, your personally packaged parcels and shipments will bring smiles throughout their travels.