A custom pop up display box is a retail display that ships flat and opens into a printed counter or shelf stand in seconds. TBPB makes them with no minimum order, and a price-beat guarantee applies if you bring a written quote for the same specifications.
How a pop up display actually works
The structure is a single die-cut sheet with scored folds. Lift the front or back panel and the tray, risers and header lock into shape, usually with tabs that tuck into slots rather than glue. That is why the display travels flat and the store never has to build anything. The trade-off is that a folded-flat design cannot carry unlimited weight. A tray of lip balms or candy bars is easy. A display holding glass jars needs a heavier board and a reinforced base.
Sizing the tray to the product
Measure the product on its flat side, then add about 1/8 inch of clearance per side if it must drop in and lift out easily. Decide how many facings you want in each row, and how many rows deep the product should sit. A header panel behind the product is where the brand name, claim and a few short lines go. Keep the height of the front lip low enough that shoppers can reach the product but high enough that it does not slide forward when the tray is nearly empty.
Board and print options
Corrugated board, usually E-flute or B-flute, is the safer choice for heavier products and for displays that will be moved by customers. Folding carton board in the 16 to 24 pt range prints cleaner and works for light, small items. Printing is full-colour CMYK with Pantone matching available for brand colours. Finishing can include matte or gloss aqueous coating, soft-touch lamination, spot UV and foil on the header. Foil and lamination look good on a hero display but add handling steps, so use them where shoppers look first.
When a different display is the better call
If the product is tall and needs to sit in rows on a counter, a counter display box with an open front is simpler. If you want shoppers to pull the product out of a tray, a custom tray display box keeps the cost of structure down. For product that hangs from a peg, look at hang tab packaging instead. Pop up is best when the display must go from flat carton to finished stand with no tools.
Shipping, storage and the store backroom
Most of the savings in a pop up display come after printing. A flat display takes a fraction of the carton space of a built one, so freight and warehouse costs fall, and a store employee can open the box and have the stand on the counter before the next customer reaches the till. Ask the retailer about footprint limits before you finalize the size. Many counters allow only a few inches of depth, and a display that overhangs the edge gets moved or binned.
- Board: E-flute or B-flute corrugated, or folding carton paperboard
- Print: CMYK, Pantone match, matte or gloss coating, soft-touch, spot UV, foil
- Structure: tuck-and-lock tabs, optional header card, die-cut front window
- Use: counter, shelf or floor stands for launches and seasonal runs
- Quantity: no minimum order, one display or thousands
Send the product dimensions and the quantity you want, even a single display, and TBPB draws the dieline and quotes it. See the full range of custom display boxes if you want to compare structures first.
Frequently asked questions
What is a pop up display box?
A pop up display box is a printed display that ships folded flat and opens into a freestanding counter or shelf stand without tools or assembly. It holds product in rows, carries a header with branding, and is used for launches, promotions and impulse items in retail stores.
Is there a minimum order for custom pop up displays?
No. TBPB has no minimum order, so you can order a single display for a store test or thousands for a rollout. Every order starts with the same step: you send the product dimensions and a quantity, and we draw the dieline and quote it.
What board should I choose for a pop up display?
Choose E-flute or B-flute corrugated for heavier products or displays that customers will handle often. Choose 16 to 24 pt folding carton board for light items where fine print detail matters. If you are unsure, send the product weight and we will recommend the board.
How do I size a pop up display?
Measure the product and add about 1/8 inch of clearance per side for easy removal. Then decide how many facings per row and how many rows deep. The tray footprint follows from that, and the header height is set by how much brand message you want visible behind the product.
Can the display be shipped already filled?
Yes, but a filled display is heavier and needs a stronger board and a base that carries the load. Many brands ship the display flat and pack product separately, so the store sets it up on arrival. Tell us your filling method when you request the quote.
Can I add foil or soft-touch to a pop up display?
Yes. Foil, soft-touch lamination, spot UV and aqueous coating are all available. They work best on the header and front lip where shoppers look first. On corrugated, coatings behave differently than on paperboard, so confirm the finish against the board before approving artwork.
More Custom Display Boxes
See the full Custom Display Boxes range, or explore related options with no minimum order and our best-price guarantee:
