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ECMA D10.41.04.00

Hexagonal Double-Wall Tray with Webbed Corners

  • Available in a wide range of custom configurations & material selection.
  • Order 1 sample. Or order 100K+ units. Or anything in between.
  • Affordable delivery across North America.
  • Design support, warehousing, testing, assembly available.
  • Widest machinery capability in America via 30+ specialist partner plants.
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Product details

Top highlights

  • Hexagonal shape with double-thick perimeter walls
  • Webbed corners prevent leaks and add rigidity
  • Unglued design ships flat but requires manual assembly

About this product

This unglued, hexagonal folding carton tray delivers a premium presentation with a completely clean interior. The double-wall construction folds over to hide all raw edges, while continuous webbed corners ensure there are no gaps for small items to escape.

Because it relies entirely on friction locks and complex inward folds, it requires manual assembly. It is an excellent choice for luxury confectionery, cosmetics, and gift sets where the unboxing experience justifies the setup time.

Common uses

  • Luxury confectionery
  • Cosmetics and beauty sets
  • Premium gift packaging
  • Dry goods requiring sealed corners

Get a quote

Share what you know. We'll take it from there. Or email us at info@herculeindustrial.com

Best Price Guarantee

Already have a packaging quote? Let us beat it.

Send us the quote you have. We will beat it for the same specifications, quantity, and delivery requirements.

Upload a competing quote

Free quote review. No obligation.

30+specialist partner plants

We supply through the plant best suited to your price, material, production, and delivery requirements.

Why we can beat a lower quote

30+ plants give us more ways to lower the price.

Each plant has different machinery, material costs, order minimums, and freight rates. Our buying volume helps us secure better pricing. We then quote through the plant that gives you the lowest total price for your requirements.

Send us your current quote. Watch us beat it.

Attach it to the quote form or email it to us. We'll review it free and send you our price.

Upload a competing quoteinfo@herculeindustrial.com
Best Price Guarantee terms

To qualify, send a written supplier quote dated within the past 30 days and addressed to your company. It must cover the same dimensions, construction, material, print, finish, quantity, tooling, freight, delivery date, and delivery location. The guarantee does not cover taxes, expired quotes, liquidation or clearance sales, or obvious pricing errors.

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Premium Presentation and Containment

Luxury Confectionery and Gift Sets

The clean, double-walled interior provides a high-end frame for premium goods. The hidden raw edges and sturdy feel elevate the unboxing experience.

Small Items and Dry Powders

Unlike trays with cut corners, the continuous webbed gussets fold inward and are trapped between the walls. This creates a sealed base corner that prevents crumbs, powders, or small components from slipping out.

Cosmetics and Beauty Collections

The unique hexagonal shape and smooth interior walls create an excellent presentation stage for skincare jars, fragrance bottles, or curated beauty sets.

Premium Corporate Gifting

The double-wall construction provides a rigid, substantial feel, making it a strong choice for presenting branded items or high-value promotional kits.

Retail and Luxury Packaging

Retail Display

The hexagonal shape stands out on retail shelves compared to standard rectangular boxes. The double walls allow for printing on both the interior and exterior using a single-sided print run, as the inner walls fold over from the outside.

Manual Packing Operations

This tray is designed for manual packing lines. The six-sided folding sequence, webbed corner management, and friction locks require operator dexterity and are not suited for standard automated cartoners.

Low-to-Medium Volume Runs

Because the star-shaped blank creates nesting gaps and assembly is entirely manual, this tray fits specialized or limited-edition runs better than high-speed commodity packing.

When to Consider Simpler or Glued Trays

High-Volume Automated Runs

If your packing line relies on high-speed automated erection, this complex manual tray is a poor fit. Consider glued crash-lock trays or simpler four-sided designs.

Cost-Sensitive Commodity Packaging

The star-shaped flat blank creates significant interlocking waste during die-cutting. For budget-sensitive projects, a standard rectangular tray uses board much more efficiently.

Board Selection and Assembly Planning

Board Quality and Flexibility

The material must withstand a 180-degree fold over the webbed corners without cracking. High-quality folding boxboard or solid bleached board handles this well. Micro-flute corrugated is often too thick and can bind the locks.

Closure and Outer Packaging

This template is a base tray only. To secure the contents for retail sale or transit, you will need to specify a separate telescopic lid, a custom sleeve, or an outer shipping carton.

Assembly Labor Allocation

The six-sided folding sequence and webbed corners require manual dexterity. Factor the slower setup time into your packing line planning.

Print and Finish Strategy

Because the inner walls fold over from the outside, a single-sided print run can cover both the exterior and the interior walls, offering a cost-effective way to create a fully branded unboxing experience.

Hexagon Proportions and Lid Additions

Adjusting the Hexagon Proportions

While the standard template creates a regular hexagon with equal sides, the proportions can be stretched to accommodate longer products while maintaining the webbed corner locks.

Locking Tongue Sizing

The terminal foot flaps can be adjusted in length to ensure they seat firmly against the base, depending on the chosen board thickness and friction requirements.

Webbed Flap Angles

The geometry of the corner webs can be tuned to change how tightly they fold inward against the outer walls, accommodating different material calipers.

Board and packing details

Friction Lock Seating

The tray holds its shape using terminal foot flaps that press into the base creases. The exact board thickness must be accounted for in the die design so these locks seat firmly without bowing the walls.

Stretched Hexagon Variant

D10.41.04.00.a (Stretched Hexagon)

This variant unlocks the width parameter independently from the length, allowing for an elongated hexagonal footprint rather than a regular, equal-sided hexagon.

Additional notes

Assembly Time Considerations

Because operators must manage six separate walls and corner gussets, factor higher labor costs and slower throughput into your packing plan compared to standard four-sided trays.

Related Hexagonal and Octagonal Trays

D10.41.01.00: Hexagonal Tray with Nib Locks

A useful alternative if you want the hexagonal shape but do not need fully sealed webbed corners, slightly reducing manual assembly effort.

D10.51.04.00: Octagonal Double-Wall Tray

A related option if your product presentation requires an eight-sided footprint with similar double-wall construction.

FAQs

Assembly and Packing

Is this tray suitable for automated packing lines?

The complex sequence of folding the outer walls, collapsing the webbed corners inward, and locking the 180-degree inner walls relies on manual assembly.

Product Fit

Is this tray liquid-tight?

While the webbed corners prevent dry powders and small items from sifting out, the folded paperboard is not sealed for liquids without a specialized barrier coating and liner.

Materials

Can I use corrugated board for this tray?

It is highly risky. The 180-degree fold-over walls and the multi-layered webbed corners create too much bulk for standard corrugated board, which will likely crush or prevent the friction locks from engaging.

Shipping and Route

Can I ship this tray through a parcel courier?

Not on its own. As an open presentation tray, it requires a secure lid and an outer shipping carton to protect contents during parcel transit.

Design Options

Does this tray come with a lid?

The base template does not include a lid. A separate telescopic cover or a custom sleeve must be designed to match the tray's final dimensions.

Assembly and Packing

How does the tray stay together without glue?

It relies entirely on friction locks. The inner fold-over walls press terminal foot flaps into the base creases, holding the structure under tension.

Print and Finish

Can the inside of the tray be printed?

Yes. Because the inner walls fold over from the outside of the blank, a single-sided print run can cover both the exterior and the interior walls.

Materials

Why does this tray use more material than a rectangular one?

The hexagonal base, combined with six double walls and webbed corners, creates a star-shaped flat blank that leaves more empty space on the sheet during die-cutting.