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EVF46002

Hexagonal Double-Wall Tray with Foot-Lock Lid

This two-piece hexagonal folding carton delivers the substantial, rigid feel of a premium presentation box while shipping entirely flat. Both the base and the lid feature double-wall construction, formed by folding inner panels over webbed corners to lock the shape in place without adhesive.

Because it relies on friction locks and a specialized foot-lock on the lid, this package requires dedicated manual assembly. It is a strong choice for luxury retail, cosmetics, and specialty confectionery where the unboxing experience justifies the fulfillment labor.

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  • Nationally competitive pricing & delivery costs.
  • Available in a wide variety of configurations.

At a glance

  • Two-piece design with a matching base and lid
  • Double-wall construction for a premium, rigid feel
  • Ships flat and requires manual folding and locking

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Product classes that fit the double-wall hexagonal shape

Luxury cosmetics and fragrances

The double-wall construction creates clean, rolled top edges that frame high-end bottles and jars. The rigid feel mimics a traditional setup box, making it appropriate for premium retail shelves.

Specialty confectionery and gifting

The hexagonal footprint stands out in bakery and confectionery displays. The foot-lock lid stays secure during retail handling but lifts off cleanly for a high-end unboxing presentation.

High-end apparel and accessories

Rolled scarves, belts, or boutique accessories fit naturally into the hexagonal base. The lack of raw paperboard edges on the interior walls protects delicate fabrics from snagging.

Limited-edition promotional kits

For influencer kits or PR boxes, the unique shape and friction-locked assembly provide a memorable unboxing sequence. The flat-shipping design keeps inbound freight manageable before the kits are assembled.

Packing labor and retail display environments

Manual assembly and kitting teams

This package is erected by hand rather than automated machinery. Packing teams must manually fold six double walls on the base and six on the lid, engaging the webbed corners and the lid's foot-locks. This labor should be factored into the overall fulfillment plan.

E-commerce fulfillment

Friction-locked trays may disengage during parcel transit. If this package is shipping directly to a consumer, it requires a fitted corrugated outer shipper to keep the lid secured and the walls intact.

Retail display and merchandising

The double-wall structure provides excellent vertical support for stacking on retail shelves. The foot-lock lid prevents accidental opening by shoppers while maintaining a clean exterior appearance.

When to compare simpler or glued hexagonal cartons

High-volume automated packing

If a packing line requires high-speed erection, a glued hexagonal carton or a standard straight-line folding carton will be more appropriate. The friction-locked double walls here are designed for manual kitting.

Direct parcel shipping without an outer box

If the primary package ships directly through parcel networks without an outer box, a corrugated mailer with a secure locking tab is a stronger choice. This folding carton is designed for presentation and requires an outer shipper for parcel delivery.

Board selection, print routing, and shipping protection

Board grade and caliper

The inner walls fold 180 degrees over the webbed corners. This requires a high-quality folding boxboard (FBB) or solid bleached board (SBB) that will not crack along the score lines. Corrugated materials are too thick for the foot-lock mechanism to engage properly.

Print and finish placement

Because the inner walls fold down into the tray, the interior sides can display continuous graphics printed on the same side of the flat blank as the exterior. This allows for full interior branding without requiring two-sided printing.

Outer shipping protection

Determine how the assembled packages will reach their final destination. For palletized retail distribution, standard master cartons are sufficient. For individual parcel delivery, plan for a dedicated corrugated outer shipper.

Insert strategy for product fit

Decide whether the product will sit loose or require stabilization. Die-cut paperboard or foam inserts can be sized to fit the hexagonal interior, keeping bottles, jars, or confectionery items centered and protected.

Adjusting lid proportions and lock clearances

Lid height and proportions

The lid can be adjusted to cover the entire base or sit partially down the side walls, depending on the desired reveal. The gap between the lid and base is closely tied to the chosen board thickness to ensure a smooth fit.

Thumb cut sizing

The radius of the thumb cuts on the lid's inner panels can be modified. These cuts provide the necessary clearance for packing teams to press the foot-locks into place during assembly.

Base depth scaling

The overall height of the base tray can be scaled to accommodate taller products. However, taller walls increase the amount of board required for the 180-degree inner folds, which impacts the flat blank size.

Packing details

Foot-lock and thumb cut mechanics

The lid secures itself using two foot-lock tabs that fold inward and engage the inner structure. Thumb cuts on the inner panels provide the necessary clearance for packing teams to press the locks into place.

Additional notes

Board grain direction and cracking risk

Because this is a hexagonal shape, folds occur at 60-degree and 120-degree angles to the board's grain. This increases the risk of cracking on certain panels, making the choice of a flexible, high-quality board critical.

Related hexagonal packaging

FAQs

Can this hexagonal box be erected by machine?

The double-wall construction and webbed corner flaps rely entirely on manual folding and friction locks. It is designed for hand-packing and kitting operations, not automated lines.

Is corrugated board an option for this tray?

Corrugated board is generally too thick for this specific design. The inner panels must fold 180 degrees, and the foot-locks require precise clearances. High-quality folding boxboard (FBB) or solid bleached board (SBB) is a better fit.

Does the foot-lock lid stay secure in the mail?

The foot-lock is designed for retail handling and presentation, not parcel transit. For parcel delivery, this carton should be placed inside a fitted corrugated outer shipper.

Can custom inserts be added to the hexagonal base?

Die-cut paperboard or foam inserts can be sized to fit the hexagonal interior, keeping bottles, jars, or confectionery items centered and protected.

Is two-sided printing required for interior graphics?

Not necessarily for the side walls. Because the inner walls fold over from the main blank, the interior sides can share the same print surface as the exterior. The bottom floor, however, would require two-sided printing or a printed insert to show graphics.

Why is a physical sample important for this box?

A physical sample verifies that the chosen board grade can handle the 180-degree folds without cracking, and that the foot-locks engage smoothly without tearing the board.

Does this package require glue during assembly?

No adhesive is needed. The base and lid are friction-locked, relying on the folded inner walls trapping the webbed corners to hold the shape.

How does the foot-lock mechanism work?

Two opposite inner walls on the lid feature specialized tabs. When folded inward, these tabs engage the inner structure, secured via thumb cuts that allow packing teams to press them into place.

Review fulfillment capacity and board preferences to ensure this double-wall presentation box aligns with the packing operation.