The Best Price Boxes makes custom full overlap slotted boxes with no minimum order, and we beat any written quote for the same specs. A full overlap box (FOL) is a corrugated shipping carton whose outer flaps are long enough to meet and cover the entire top and bottom, giving you a double layer of board at both ends.
Custom full overlap box specs
| Spec | Detail |
|---|---|
| Minimum order | None, one box or thousands |
| Style | Slotted corrugated carton, outer flaps fully overlap |
| Strength | Double board thickness at top and bottom |
| Size | Custom inside dimensions |
| Plain kraft or printed; ask us to confirm your artwork method | |
| Proof | Dieline and digital proof, plus a sample of the structure |
How a full overlap box differs from a standard RSC
A regular slotted container (RSC) has outer flaps that each reach only to the center, so the two flaps meet in a seam with a gap in the middle. A full overlap box has flaps that each span the whole width, so they stack on top of each other and the entire panel is two boards thick.
That extra layer is not decoration. It spreads the load across the top of the carton, so a stack of boxes presses on a solid panel instead of a taped seam. It also stiffens the box against punctures and corner hits.
When FOL is worth the extra board
Use it for heavy goods, items that get stacked on pallets, and drop-shipped products that take rough handling. Cast iron cookware, bottled goods, equipment parts and bulk food ingredients are typical. If your product is light and ships in a parcel box, an FOL is overkill and uses more board than you need. A mailer box or a plain shipper does that job for less.
The trade-off is simple: more board means more cost and a bit more weight. We would rather talk you out of FOL on a 2-pound item than sell it to you, and the quote form is the fastest place to settle that.
Board grade and how to choose it
Corrugated strength is rated by edge crush test (ECT) for stacking and by burst strength for puncture. Single-wall board in a lower ECT works for lighter loads. Heavy or tall stacks usually call for double-wall board. Our guide to corrugated cardboard explains flute types and walls. Tell us the product weight and how many boxes you stack, and we will match the grade.
How to measure for a custom FOL
Measure the product, not the old box. Record length, width and height of the item, add the padding you want on every side, and list those as inside dimensions, length first, then width, then height. Add space for dividers or a packaging insert if the product needs one. We turn your numbers into a dieline so you see the flat layout before anything is cut.
How to order
Send your inside dimensions, product weight and quantity through the quote form, even if the quantity is one. If you have a written quote from another supplier for the same specs, attach it and we will beat it. Free design help and free samples are part of how we work. For other corrugated styles, browse our corrugated boxes.
Questions buyers ask
Is there a minimum order for full overlap boxes?
No. We make custom full overlap slotted boxes with no minimum order, so you can order a single box to test the fit before committing to a larger run.
What is the difference between FOL and RSC?
An RSC has flaps that only meet in the middle, leaving a seam. A full overlap box has flaps that cover the whole top and bottom, so the panel is two layers of board thick. FOL stacks and survives rough handling better.
Can I print on a full overlap box?
Yes, plain kraft and printed options are available. Printing method and coverage depend on the board, so send your artwork and we will confirm what works for your spec before you approve a proof.
What size should I order?
Order by inside dimensions that match your product plus the padding you want. Measure the item, add clearance on each side, and send length, width and height. We check the numbers against the board before quoting.