Deciding the box style for your products is vital as it influences both their look and how well they are protected during shipping. Both RSC boxes and die cut boxes are two popular choices that come with their pros and cons. So the big question is — which one aligns better with your business requirements?

1. What is an RSC Box?

RSC stands for Regular Slotted Container in corrugated packaging. It’s a box style made from one piece of corrugated fiberboard with equal-length flaps on top and bottom that meet at the middle when closed. The design makes them easy to seal with tape, and they can hold a wide range of heavy items in various sizes. This makes RSC boxes a popular choice for shipping items. Also, RSC boxes are typically made from 100% recyclable materials.

Example of a RSC box and its dieline, showing how it is folded in 3D mockup.

1.1 Example Usage of RSC Boxes

RSC boxes are perfect for secondary packaging and shipping a wide range of items. Here are some examples:

  • Consumer goods
  • Appliances
  • Toys
  • Office supplies
  • Electronics
  • Beverages
  • Automotive and industrial products
  • Fragile products (need extra protection, like void fillers)
Applications of RSC Boxes

1.2 Key Benefits of RSC Boxes

RSC boxes have many advantages for packaging. They are sturdy, protecting products well, and very versatile. They’re ideal for shipping worldwide and can be customized to showcase your brand with simple printed designs and colors.

  • Cost-effective: RSC boxes are affordable and waste little material
  • Easy to Put Together: RSC boxes are simple to fold up and seal with tape
  • Strong & Durable: Made from corrugated materials that offer maximum protection with no areas of entry
  • Versatility: RSC boxes meet diverse packaging needs in different industries. Their design and materials suit various products.
  • Quick Turn-around: Custom RSC boxes offer quick quotes, low minimum order quantity, and standard sizes for all needs
  • Sustainable: They are made from 100% recyclable material, making them eco-friendly

2. What Is a Die Cut Box?

Die cut boxes are special packaging made to fit specific shapes and sizes for your product. They are cut using a die-cutting machine, giving you more design freedom and structural integrity than regular boxes.

For example, you can have self-locking tabs that eliminate the need for tape, or windows that showcase your product for branding and display purposes. With die cut boxes, you can create tailored packaging that meets your unique needs, whether for shipping, shelf display, or both.

Example of a die cut box and its dieline, showing how it is folded in 3D mockup.

2.1 Example Usage of Die Cut Boxes

Die cut boxes are highly customizable and are made to fit your product snugly. This makes them ideal for high-end products or brands that need a distinct identity. They can serve as both primary and secondary packaging. Here are some examples:

  • Luxury cosmetics and skincare products
  • High-end electronics and gadgets
  • Gourmet food items and specialty beverages
  • Delicate or fragile products that need extra care during shipping
Applications of die cut boxes

2.2 Key Benefits of Die Cut Boxes

Die cut boxes have many advantages over regular boxes:

  • Cost-Effective for Shipping: Die cut boxes are designed to minimizes material use, reducing package size and lowering costs. This custom fit approach yields compact, economical shipping solutions for products of all shapes
  • Maximum Protection: Die cut boxes with box inserts snugly secure products, providing better protection and a great appearance. They offer excellent protection, making them ideal for luxury items.
  • Customization & Branding: Custom-made die cut boxes help your brand stand out and make the unboxing experience more memorable.
  • Less Waste: Die cut boxes often need less tape and packing materials than regular boxes
  • Require No Tape for Assembly: The base of the carton simply folds out and locks into place, making assembly minimal

3. Choosing Between Custom Die Cut Boxes and RSC Boxes

Deciding between RSC and die cut boxes depends on what your business needs. You need to think about your budget, the type of product, its weight, how much protection it needs, how easy it is to put the box together, shipping, storage, and what your customers expect. We’ve summarized the key points below to help you make a decision.

Choose RSC Boxes for Cost-Effectiveness and Versatility

RSC boxes are suitable for a wide range of products. They are more affordable due to lower costs for tools, print plates, and production. Customization options include various sizes and flutes, and printing on the inside/outside of the box.

Choose Die Cut Boxes for Customization and Enhanced Protection

Die cut boxes provide a high level of customization, allowing for a perfect fit around products. This reduces the need for additional packing materials like tape and enhances the unboxing experience for customers. Although die cut boxes may have higher initial costs than RSC boxes due to custom dies, their long-term benefits, such as reusability and improved packaging efficiency, can justify the expense. They are ideal for premium products, as they can be customized with uniquely shaped and designed boxes for better presentation.

Table comparison of RSC Boxes and Die Cut Boxes.

3.3 Additional Considerations

  • For packing fragile items, we recommend adding extra void fillers. Use bubble wrap, air pillows, packing peanuts, or packing paper for RSC boxes. For die cut boxes, use custom foam or corrugated inserts.
  • You may also want to consider looking into other box styles that may better align with your requirements. See our corrugated master guide for details.

4. FAQ

What is the Difference Between RSC and HSC boxes?

HSC boxes (Half Slotted Container) are made from one piece corrugated cardboard, similar to RSC boxes. However, unlike RSC boxes, HSC boxes have flaps only on the bottom, leaving the top open. This design allows for easy access to contents and can be more economical due to reduced material usage.

RSC Box vs. HSC Box

What is the Difference Between RSC and FOL Boxes?

FOL boxes (Full Overlap Slotted Containers) are similar to RSC boxes in that they’re made from one piece of corrugated cardboard. However, FOL boxes have flaps that fully overlap at the top and bottom, giving them extra strength and protection. This makes them perfect for heavy, fragile, or high-value items that may be handled roughly. While FOL boxes use more material and are more expensive than RSC boxes, they offer better protection against crushing and impact.

RSC Box vs. FOL Box

What Are the Other Types of Corrugated Box Styles?

For a comprehensive guide on the various types of corrugated box styles, please visit the corrugated master guide here.