Custom plastic boxes
Custom Plastic Boxes Made to Your Size
A box cut from pre-colored plastic sheet to the length, width and height you specify, with the openings, lid, bosses and printing your product needs. One box or five thousand, and no mold in between.
Custom size plastic box
A custom plastic box is a flat pattern with the right bends.
Catalog boxes come in the sizes someone else chose, and the search for one that fits ends with a board that is too long by a few millimeters or a lid with no room for the display. Toolless makes a custom plastic box to your dimensions. The sheet is CNC machined with every opening, scored on a V-groove saw along each bend line, folded on a computerized thermal bender and solvent bonded, so the size is a number in a program rather than a cavity in steel.
The economics follow from that. There is no tooling to buy, a dimension change costs a program edit, and quantities from one unit to 10,000 come off the same machines. Custom made plastic boxes from Toolless start at stock ABS in white, black, light grey and dark grey and go through flame-retardant, transparent and custom-color materials as the application demands. The C Box and U Box designs are the fastest route; a fully custom enclosure is the most flexible.
Three constructions
Pick the box by how it opens.
Every box starts from the same sheet. The piece count and the lid decide the price and the assembly.
Two pieces
C Box
Two C-shaped halves that snap together over the board. The most economical Toolless box, with the circuit board on bosses or in grooves and an optional bonded seal.
C Box
Four pieces
U Box
A U-shaped body, a matching cover and two end panels. Suits long, narrow or unusually deep boards, with curved fronts and slot patterns available.
U Box
Open top
Bins and containers
Trays, cassettes and storage bins bent from one sheet with bonded end walls, for parts handling, instruments and retail fixtures.
BinsOptions
Everything a stock box makes you add later.
The opening for a connector, the standoff under a board and the logo on the lid are all part of the program, so they arrive finished. Send the board and the connector list and the box is sized around them; send CAD and the openings are placed from it.
- Cutouts for connectors, switches, displays and cable glands on any face
- Bosses with brass inserts or self-tapping screws, or board grooves for a fastener-free build
- Acrylic windows bonded from the rear, light pipes for status LEDs
- Vent slot patterns sized for fan cooling
- Hinges, latches, magnets and key locks from standard hardware
- Full-color digital printing, engraving and two-tone panels
- EMI and RFI conductive coating on the inside
Ordering
From dimensions to delivered boxes.
Size it
Give length, width and height, or the board outline and the tallest component. The Product Designer turns dimensions into a downloadable C Box or U Box CAD model in minutes.
Add the features
Mark the cutouts, bosses, windows and printing. An engineer returns a 3D model in STEP, IGES, STL or SolidWorks for approval before anything is cut.
Prototype
3 to 21 working days depending on complexity. One or two units carry a setup charge; the process is most economical from 100 to 10,000 pieces.
Release production
A blanket order of 10 to 10,000 boxes ships in releases three weeks after each PO. A size change between releases is a program edit.
Custom box or catalog box
What changes when the box is made for the product.
A catalog box is cheap until the labor to modify it is counted. A custom plastic box arrives assembled, cut and printed, and the same program repeats it for the next order. Customers who have made the switch write about it on the testimonials page.
Related
Keep reading.
Standard enclosures
C Box and U Box, resized and finished for your board.
Standard enclosures
Handheld enclosures
Boxes shaped for the hand, with curves in one direction.
Handheld
Wall-mount boxes
Vented housings with mounting ears and cable entries.
Wall mount
Portfolio
Boxes and enclosures from the shop floor, by market.
BrowseQuestions
Custom plastic boxes, answered.
Can I order a single custom plastic box?
Yes. There is no minimum order. One or two units carry a setup charge, and the price per box falls quickly from there; the process is at its most economical between 100 and 10,000 units.
How big or small can the box be?
Sheet from 2 mm to about 12 mm covers small handheld boxes through floor-standing kiosk shells. The longest single bend is 40 inches. Tell us the dimensions and an engineer will confirm the construction at review.
Which material should I choose for a plastic box?
General-purpose ABS is used for 80 percent of production and is stocked in four colors. Flame-retardant ABS or Boltaron for UL94 V-0, polycarbonate for impact and transparency, acrylic for display pieces. Custom colors are sourced with a minimum of around 2,000 pounds of material.
Can the box have a hinged or removable lid?
Yes. Lids snap on, screw down onto brass inserts, hinge on metal or solvent-bonded acrylic hinges, or bond permanently. Latches, magnets and key locks come from standard hardware, which costs less than a custom feature and is easier to service.
Start your enclosure
Send the board. We’ll send the box.
Quotes come from an engineer, not a form robot. Attach CAD, photos or a sketch and we reply within one business day.