7 Rigid box design mistakes and tips to fix easily

06/06/2025

A rigid box design offers more than just product protection, the packaging deliver luxury, brand identity, and a lasting impression. Even premium rigid box packaging can have mistakes if the design does not meet user expectations or market standards.

In this article, Khang Thanh will remind you of 7 common mistakes in rigid gift box packaging design and offer easy tips to effectively fix bad design issues.

1. Complex design can confuse users

Many businesses want their gift boxes to look fancy. However, they often make packaging that is hard to open or use. The common mistakes include extra flaps, misplaced magnetic locks, and strange opening and closing mechanisms.

# Design error:

In fact, if well-developed luxury paper packaging makes users excited and curious, this can increase the accessibility of the package. However, these designs can get negative feedback if customers take too long to figure out how to open the box.

In addition, designing a complex rigid box design structure can increase costs and reduce the effectiveness of product protection.

# Solution:

Discuss carefully with the packaging company's R&D department so that they can advise an optimization plan
Produce a sample and experience opening and closing the rigid gift box yourself to have conclusions

Common mistake include complex magnetic locks and strange opening-closing mechanisms.

2. Neglecting fit and protection of rigid box packaging

Some rigid box designs prioritize aesthetics over functionality. Specifically, the gift box looks good but doesn’t protect well, or is too spacious or too cramped for the product.

# Reason it fails:

Without proper internal structure, your product risks shifting, breaking, or looking cheap—leading to business complaints.

This mistake often happens with high-end rigid box designs. This includes perfume packaging, luxury wine boxes, and business gift boxes.

# How to fix:

Make a real sample box before mass production
Choose an easily customized tray such as a foam insert, EVA, velvet, or paper tray

>>> Key considerations when designing big gift boxes with lids

Designing rigid box and tray that are too large for the size of the wine bottle will cause the product to shift easily.

3. Missing essential information

Other rigid box packaging mistakes often include missing essential information such as instructions for use, manufacturing and expiration date, etc. Even worse, the luxury packaging missing brand names, logos, and trademarks.

# Cons:

A poor design creates confusion and lacks transparency. Moreover, inconsistent images reduce trust and lead to customer complaints about legitimacy, and unclear communication.

# Solutions:

Build a brand identity for the packaging manufacturer to follow
Should only choose 1 to 2 main colors, and 1 main font to avoid confusion
Making test samples to adjust before mass production

Must note the necessary information when printing high-end box packaging.

4. Forgetting wholesale and shipping efficiency

Creating a rigid box that looks good but is bulky can be a big issue. This is especially true for wholesale, B2C, and B2B industries. It can make stacking and shipping less efficient.

# Reason it fails:

Even the most beautiful gift box can be a problem. This happens if it raises shipping costs or if someone damages it easily during shipping.

# How to fix:

Focus on making rigid box designs that save space and stack well. Examples include folding rigid boxes, base and lid rigid boxes, and magnetic luxury gift boxes.
Create shapes on the sides of the box to increase the ability to fold
Design magnets to shape the box when needed

>>> Newest and beautiful boxes for presents trends 2025

Foldable rigid boxes are always the perfect packaging solution to save costs and storage space.

5. Over-effects rigid box packaging

Adding too many finishing effects can make luxury box packaging look messy. Effects like foil stamping, UV coating, debossing, and embossing should be used carefully. Moreover, it can make box design detract from the luxury and unnecessarily increase production costs.

# Cons:

For minimalist, elegant, and luxurious gift boxes, designers can consider overdoing the effects a design mistake. Simply, putting too many printing effects can make your box look garish and outdated.

# Solutions:

Choose finishes that fit your brand. For example, use matte lamination for premium skincare gift boxes. Use spot UV coating for tech packaging. Use glitter coating for high-end Christmas gift boxes
Use a simple formula: apply only 3 effects to 1 packaging design. Choose glossy or matte lamination. Add UV or hot foil stamping for details. You can also use glitter to enhance the effect, but it's optional

The packaging effect of Ballantine's 18 rigid wine box shows minimalism, luxury and class.

6. Choosing wrong material for rigid gift box

Rigid box packaging is known for its luxury, sturdiness, and strength. To save money, some businesses have picked low-quality materials. They use paper that is too light or has a poor finish. This choice goes against the goal of high-end packaging.

# Why it fails:

This packaging design mistake will reduce customers' expectations of receiving elegant, neat, and high-quality rigid gift boxes. Also, for high-end brands, using the wrong paper can hurt the product. Thin and easily wrinkled paper can lower the brand's value.

# Solution:

Always prioritize using high-quality paper material with a basic weight of 800-1500 gsm
To optimize costs, you can laminate the paper on chipboard to maintain its rigidity
Gloss lamination can protect the surface and increase the load-bearing capacity of the gift packaging

Using kraft paper laminated with chipboard helps gift box retain rustic look while still being sturdy.

7. Rigid packaging lack of uniqueness compared to competitors

In industries like cosmetics, tech accessories, or luxury goods, using rigid gift packaging that is too simple and impersonal can make your product invisible.

# Design error:

Rigid packaging aims to elevate your product and create a memorable impression. If your box looks like every other brand, the boxes can lose its marketing power. For that reason, the mistake can reduce brand recognition and customer engagement.

A package with a design that is too common will not stand out next to competitors in the same booth. Specifically, your rigid box will not attract customers, which will reduce the display function of the packaging.

# How to fix:

Updating the latest packaging trends
Work with experienced packaging manufacturers to create unique structural designs, distinctive and colors.
Bring life to rigid packaging by building brand stories, limited edition gift boxes, campaign packaging, and seasonal rigid boxes...

>>> 3 Types of rigid boxes for premium packaging solutions

Increase the competitiveness and marketing with uniquely designed rigid box packaging.

Choose a reputable packaging company to minimize risks

A great way to avoid mistakes when designing rigid boxes is to work with a trusted manufacturer. A good packaging partner helps ensure product quality. They also save you time, money, and effort from start to finish.

Khang Thanh has over 20 years of experience. Our team has more than 200 skilled employees. We serve both local and international customers. We can help you solve all your problems with:

R&D team to turn your ideas into reality
Rapid prototyping for better decision-making
Advanced machinery and custom rigid box capabilities
Update the latest packaging trends

>>> 2025 price guide: Cost of custom rigid boxes from Vietnam

When you make your next rigid gift box, keep this in mind: design is not just about looks. It is also about communication, experience, and function. Hopefully, by understanding the 7 mistakes above, you will minimize packaging design mistakes.

If your business doesn't know where to start, Khang Thanh is ready to advise:

KHANG THANH – HOUSE OF PACKAGING
Tel: +84 (0) 77 8878 222
Email: info@khangthanh.com