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Project Overview

Packaging design combines aesthetics with technical requirements. This guide covers boxes, labels, bags, and other packaging materials.
Time to Complete: 2-6 hours (varies by complexity) Difficulty: Advanced Recommendation: Work closely with packaging manufacturer

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Types of Packaging

What: Flat cardstock folded into boxesCommon types:
  • Straight tuck end (STE)
  • Reverse tuck end (RTE)
  • Auto-lock bottom
  • Gable top
  • Pillow box
Materials: Cardstock (12-24 pt)Printing: Offset or digitalUse for: Product boxes, retail packaging, gift boxesComplexity: High (requires dielines)

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Working with Dielines

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What is a Dieline?

Definition: Template showing cut/score/fold lines for packaging Components:
  • Die cut lines (solid): Where to cut
  • Score/fold lines (dashed): Where to fold
  • Safety area: Keep important content here
  • Bleed area: Extend design here
Example (simplified box): 
┌─────────────────┐
│    ┌─────┐      │  Solid line = Cut
│    │     │      │  Dashed line = Fold
│────┼─────┼────  │
│    │     │      │
│    └─────┘      │
└─────────────────┘

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Getting Dielines

1

From Packaging Manufacturer

Best source: Your chosen packaging supplierRequest: “Can you provide a dieline template?”Format: Usually AI (Illustrator), PDF, or EPSBenefit: Exact specifications for their equipment✅ Recommended approach
2

Industry Standard Templates

Sources:
  • Packhelp
  • Packlane
  • BoxStructure.com
  • ArtiosCAD
Caution: Verify dimensions match your needsCustomize: May need adjustment
3

Custom Creation

Advanced: Create your own in CAD softwareTools: ArtiosCAD, Boxshot, Cape PackNot recommended: Unless experiencedBetter: Get from manufacturer

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Importing Dieline to Figma

1

Receive Dieline File

Formats: AI, EPS, PDF, or SVGFrom manufacturer or template library
2

Convert if Needed

If AI/EPS:
  • Open in Illustrator
  • Save as PDF or SVG
  • Export at actual size (100% scale)
If PDF: Can import directly to FigmaImportant: Preserve dimensions (no scaling)
3

Import to Figma

Method 1: Drag PDF/SVG into FigmaMethod 2: File → Place Image → Select fileResult: Dieline imported as vector (if SVG) or image (if PDF)
4

Verify Dimensions

Critical: Check size matches specificationExample: If dieline should be 12” × 8”, verify in FigmaFix if wrong: Resize to exact dimensionsLock: Lock layer so you don’t accidentally move it
5

Organize Layers

Create layers:
  • Background: Dieline template (locked)
  • Design: Your artwork (editable)
  • Guides: Cut/fold/safety lines (reference)
Lock dieline: So you don’t modify itDesign above: Create artwork on top

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Box Design Specifications

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Common Box Sizes

Product TypeTypical Box SizeCardstock Weight
Small item (jewelry)2” × 2” × 1”18-24 pt
Standard product4” × 4” × 2”16-20 pt
Food box6” × 4” × 3”18-24 pt
Large retail10” × 8” × 4”20-28 pt
Shipping boxVarious200+ lb test (corrugated)

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Critical Zones

Amount: 0.125” (3mm) beyond die cut lineWhy: Ensures no white edges after cuttingExtend: All background colors/images to bleedExample:
Die cut ──→ │ ← 0.125" bleed extends beyond
Check: All edges have bleed
Amount: 0.125-0.25” (3-6mm) inside die cutWhy: Cutting tolerance, folding distortionKeep inside:
  • All text
  • Logos
  • Important graphics
  • Barcodes
Avoid: Critical content at fold linesExample:
Die cut ──→ │ ←── 0.25" safety
            │ [SAFE AREA FOR TEXT]
Marking: Dashed or dotted linesProcess: Score lines created during die-cuttingDesign consideration:
  • Avoid placing important text on folds
  • Keep 0.125” clear on each side of fold
  • Design may shift at fold
Test: Print and fold mock-up
What: Flaps where adhesive is appliedKeep clear: No important contentUsually: Plain or simple patternMarked on dieline: Shows where glue goesDesign: Background color/pattern only

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Label Design

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Label Types & Specifications

Shape: Rectangle wrapping around bottleMeasurements needed:
  • Bottle circumference
  • Label height
  • Overlap (0.25-0.5”)
Example (3” diameter bottle):
Circumference = π × D = 3.14 × 3" = 9.42"
Label width = 9.42" + 0.5" (overlap) = 9.92"
Considerations:
  • Seam placement (usually back)
  • Label curls with bottle
  • Front panel prominent
Format: Rectangular with bleed

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Label Materials

Characteristics:
  • Natural texture
  • Matte finish
  • Absorbs ink
Best for: Craft products, organic, eco-brandsNot for: Wet/refrigerated products

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Color & Printing Considerations

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Pantone for Brand Consistency

Problem: Packaging requires exact brand colorsSolution: Use Pantone spot colorsBenefits:
  • Consistent across production runs
  • Matches brand guidelines
  • Vibrant colors beyond CMYK
Essential for: Brand colors, logosSee Spot Colors Guide

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Special Finishes

Effect: Glossy coating on specific areasApplication: Matte base + gloss highlightsUse for: Logos, text, patternsFeel: Tactile, premiumCost: Moderate add-on

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Regulatory Requirements

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Food & Beverage Packaging

Legal requirements vary by country and product typeAlways consult:
  • Food safety regulations
  • Labeling laws
  • Industry guidelines
  • Legal professional if unsure
Common requirements (US/FDA):
  • Product name
  • Net quantity
  • Ingredient list (in order)
  • Allergen warnings
  • Nutrition facts
  • Manufacturer info
  • Country of origin
  • Lot/batch code
  • Expiration date
Font sizes: Minimum sizes required Placement: Specific locations mandated Get review: Legal/compliance check before printing

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Barcodes

Required for: Retail salesObtain from: GS1 (gs1.org)Size: Minimum 1.469” × 1.02” (UPC-A at 100%)Placement:
  • Bottom right (preferred)
  • Clear space around (quiet zone)
  • White background
Quality: High resolution, vector if possibleTest: Scan before mass production

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Mock-Ups & Proofing

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Physical Mock-Ups

1

Print Flat

Print dieline with your design at actual sizePrinter: Home or office printer OK for mock-upPaper: Regular paper fine for testing
2

Cut and Fold

Cut: Along die cut linesScore: Use ruler and bone folder on fold linesFold: Assemble box/package
3

Evaluate

Check:
  • Does it fold correctly?
  • Content in right places?
  • Text readable?
  • Design looks good assembled?
  • Any issues at folds?
Adjust: Fix issues in Figma, repeat

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Digital 3D Mock-Ups

Tools:
  • Boxshot
  • Packly
  • Adobe Dimension
  • Online mock-up generators
Benefits:
  • Realistic rendering
  • Multiple angles
  • Client presentations
  • Marketing images
Limitation: Not a substitute for physical mock-up

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Printing & Production

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Minimum Order Quantities

Package TypeTypical MOQCost Range
Custom boxes1000-5000$0.50-3.00 each
Labels (roll)500-1000$0.05-0.50 each
Pouches/bags1000-5000$0.20-1.00 each
Short-run digital100-500Higher per-unit
Digital printing: Lower MOQ, higher unit cost Offset printing: Higher MOQ, lower unit cost

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Lead Times

Design approval: 1-2 weeks Die creation (if new): 1-2 weeks Printing: 1-3 weeks Shipping: 1-2 weeks Total: 4-8 weeks typical Rush options: Available at premium cost

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Step-by-Step: Simple Box

1

Get Dieline from Manufacturer

Contact packaging supplier, request dieline templateReceive AI, PDF, or SVG file
2

Import to Figma

Create frame matching dieline dimensionsImport dieline as background layerLock dieline layer
3

Add Guides

Mark:
  • Die cut lines
  • Fold lines
  • Safety zones (0.25” inside)
  • Bleed areas (0.125” outside)
Use Figma guides or shapes
4

Design Panels

Identify panels:
  • Front
  • Back
  • Sides
  • Top/bottom flaps
Design each panel:
  • Brand elements
  • Product info
  • Graphics
Respect: Safety zones, fold lines
5

Add Regulatory Elements

Include (if applicable):
  • Barcode
  • Ingredients
  • Warnings
  • Certifications
  • Contact info
6

Extend to Bleed

Ensure: All backgrounds/colors extend 0.125” beyond die cutNo white gaps: After cutting
7

Export

Printery:
  • CMYK conversion ✓
  • Spot colors (if used) ✓
  • 300 DPI ✓
  • Crop marks ✓
Submit: PDF to manufacturerInclude: Printing specifications
8

Proof Before Production

Request: Physical proof from printerVerify:
  • Colors accurate
  • Folds correctly
  • No errors
Approve: Before full production run

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Packaging Design Checklist

  • Dieline obtained: From manufacturer or verified source
  • Dimensions verified: Matches product and specifications
  • Bleed added: 0.125” (3mm) beyond cut lines
  • Safety zones respected: 0.25” (6mm) inside cut/fold lines
  • All text readable: Minimum 8pt, larger for regulatory
  • Fold lines clear: No important content on folds
  • Colors specified: CMYK or Pantone as appropriate
  • Special finishes noted: UV, foil, emboss (if applicable)
  • Regulatory compliance: All required information included
  • Barcode included: Correct size, placement, scannability
  • Physical mock-up created: Printed, cut, folded, tested
  • Images 300 DPI: All graphics high resolution
  • Manufacturer specs met: Confirmed requirements
  • Proof approved: Physical sample checked before production

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Learn More

Spot Colors

Brand color accuracy with Pantone

Color Management

Professional color workflows

Advanced Options

Custom configurations

Design to Print

Professional design principles
Pro Tip: Always, always, ALWAYS order a physical proof before mass production. The 50−100proofcostcansaveyoufrom50-100 proof cost can save you from 5,000+ in wasted packaging!