I have been hording boxes for a while now with the idea of taking them apart to work out how they are made. Well today is the day I finally send them on to the recycling bin. I have always found that one of the best ways to learn is to look at how professional products are made. Sometimes there goals are different than yours but for sure they have spent much more time thinking about how to manufacturer a product. Anyway in the spirit of learning from others here are the boxes I collected. As I get time I'm going to try to sketch each up and add it to the list.
This is a standard box that is 23 cm x 15.5 cm x 13.5 cm and made from 1.8 mm corrugated cardboard. It has one glued edge and the top and bottom is taped together. Notice that they have left a gap of a little more than 2x the thickness of the material between the flaps. That both stops the flaps from hitting each other when the box is closed and it makes the tolerances on assembly much looser.
This box is 27.5 cm x 17 cm x 3 cm and is made from a very cheap 1.75 mm corrugated cardboard that pulls apart easily. It is similar to the Amazon box with one glued edge, but it uses a unique flap for the bottom that tucks together without glue while remaining relatively strong. The top has a flap that tucks in place as well but it is designed to be easily opened.
This box assembles without glue while being almost as efficient on material as the Amazon box. It is not as sturdy, in particular once the lid is released it basically falls apart, but it is functional. It has an outer dimension of 17 cm x 13 cm x 9.5 cm and is made from 2.2 mm corrugated cardboard. Notice that the sides are shorter than the back, by just enough for the bottom and top tabs to fit.
Book of the Month box
This box is 27 cm x 18.5 cm x 6 cm and is made from 2.2 mm thick corrugated cardboard. Like the Funco box it is designed to be assembled without glue, but it adds flaps on the side that lock the front and back in place so the box won't come apart on its own when the lid is released. The lid has an interesting tab system that makes it sturdy but easy to open. This box is made to ship and only requires a single piece of tape at the front to hold it secure in transport.
Super Chewer box
This box is 25 cm x 19.5 cm x 10x5 cm and is made from 2.9 mm thick corrugated cardboard, the insert is made from a 0.3 mm heavy cardstock like paper. It is very similar in design to the book of the month box but it has a unique custom insert to spice things up. It also ships as shown with only a single piece of tape to hold it together.
This is one of the more unique boxes, It is designed to hold a vase of flowers and is made to store flat and be easily assembled when needed. It has multiple glued edges, and unfolds almost like origami. It also has several perforations that were cut into it to make it more flexible. These were cut with a knife but could just as easily been cut with a laser. This is very similar to how a restaurant to-go drink carrier would be designed. It has dimensions of 20.5 cm x 20.5 cm x 12.5 cm and is made from 0.7 mm solid cardboard.
Here is an interesting one, they manage to create a complex shape out of paper and some unique fold lines. It is also a unique mix of vacuum formed plastic and paper.