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EVF90001

Custom Paperboard Sleeve

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

Zero-capacity pocket for flat media and cards
Open end with thumb cut for easy extraction
Glued side seams for a clean presentation

About this product

This flat paperboard sleeve provides a clean, zero-capacity pocket for gift cards, hotel keys, booklets, and flat media. It features a single open end with a semi-circular thumb cut, allowing users to easily pinch and slide out the contents.

Because it lacks side walls or gussets, the sleeve relies entirely on the natural flex of the paperboard to hold items. It is designed for hand-to-hand distribution or as an insert within a larger package, rather than as a standalone shipping mailer.

Common uses

Gift cards and hotel keycards.
Software discs or flat media.
Instruction manuals inserted into master cartons.

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Size and quantity

Detailed dimensions

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Width (opening edge)

Length (depth)

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Materials and print

Paperboard preference

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Paperboard details

Print and artwork

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Print, finish, or artwork details

Shipping or storage context

Custom changes or unusual needs

What type of item will go inside this sleeve?

Do you want the standard thumb cutout on the open edge?

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Presentation for cards, keys, and flat media

Gift cards and hotel keys

The flat profile provides a clean, printable surface for branding while making it easy to hand a small, flat item directly to a customer.

Software discs and digital media

Provides a simple, zero-capacity cover for CDs, DVDs, or flat digital media, keeping the surface protected from direct scuffing before use.

Instruction manuals and warranty cards

Acts as an organized inner sleeve for thin documents placed inside a larger master carton alongside a main product.

Event passes and ticketing

Offers a professional presentation for VIP passes, event tickets, or flat lanyards distributed at registration desks.

Retail handouts and kitting inserts

Retail and hospitality

Provides a branded touchpoint for small, flat items handed directly to customers at a desk or checkout counter.

Kitting and fulfillment

Keeps thin manuals or warranty cards organized and prevents them from slipping under heavier items inside a master carton.

Software and media distribution

Serves as a lightweight, printable jacket for physical media that does not require a rigid plastic case.

Situations that require gusseted pockets or rigid mailers

Thicker items or multiple booklets

This sleeve has zero capacity. Forcing thick items inside will bow the board and stress the glue seams. If your product has depth, look at a gusseted pocket instead.

Parcel shipping

This sleeve has no closure flap and offers no crush protection for postal networks. If you are mailing a booklet or card directly, check rigid mailers.

Board caliper, friction, and print surface choices

Board thickness

Folding carton board like FBB or SBS is typical. If the board is too thick, the sleeve will not fold completely flat; if it is too thin, it will not protect the contents.

Print and finish

The flat front and back panels offer uninterrupted space for high-quality printing, foil, or varnish to elevate the presentation.

Internal clearance and friction

The internal width should be slightly larger than the product to allow it to slide in, but tight enough that friction keeps it from falling out easily.

Packing method

Consider whether the items will be inserted by hand or by automated equipment, as this can change the required clearance and board stiffness.

Thumb cut and glue flap adjustments

Thumb cut radius

The semi-circular cutout can be widened or narrowed based on the size of the inserted item and the desired grip area for the user.

Glue flap width

The internal side flaps can be adjusted to match specific straight-line folder-gluer requirements or to change how far the product can slide side-to-side.

Straight-edge opening

The thumb cut can be removed entirely for a straight, uninterrupted edge, though this makes retrieving flush-fitting cards more difficult.

Packing details

High-speed straight-line gluing

The simple two-fold sequence makes this sleeve fast to run on straight-line folder-gluers.

Additional notes

Insert clearance and friction

The internal width should be slightly larger than your product to allow it to slide in, but tight enough that friction keeps it from falling out easily.

FAQs

Can this sleeve hold a USB drive or small product?

Only if it is extremely flat. The sleeve has zero capacity, so anything thicker than a few stacked cards will cause the board to bow and may rupture the glued side seams.

Does this sleeve seal for shipping?

No, one end remains completely open. It is meant for hand distribution or as an inner pack, not as an outer shipping mailer.

Can the inside of the sleeve be printed?

Yes, but because the sleeve is glued shut, interior printing is only visible through the open edge and thumb cut. Most branding is focused on the exterior panels.

Is this suitable for short runs?

Yes. While fast to run on straight-line gluers for large automated orders, the simple flat shape is also easy to die-cut and assemble for short digital trials.

Can this be made from corrugated board?

Generally no. Corrugated board is too thick for a zero-capacity sleeve and will not fold flat or glue cleanly in this configuration. It requires folding carton board like FBB or SBS.

Can the thumb cut be removed?

Yes, the thumb cut can be removed if you prefer a straight edge, though it makes retrieving flush-fitting cards more difficult for the user.

Will the paperboard scratch delicate items like discs?

Standard uncoated board can be abrasive to sensitive surfaces. If you are packing optical media or glossy cards, discuss smooth coatings or specific board grades to reduce scuffing.

How does the sleeve stay closed?

The sleeve is glued along two internal side seams during manufacturing. The top edge remains permanently open for loading and retrieval.