Complete step-by-step instructions for assembling a one-piece simplex box. Learn how to properly fold and secure all components for professional results.
-
Pre-break the window panel corners
The window is maximized for size so there is not a lot of paperboard on the top panel. We are going to pre-break the paperboard fibers on the scores of this more delicate panel first. Lay the box so the folded-in sides are running parallel to your torso. Pin the window panel down by placing your fingertips just below the score line between the gusset and side panel of the lid.
-
Fold adjacent panels to 90°
Turn the box on the table 90° so the side is now parallel to your torso. With your fingertips press the "frame" of the window panel to the table and with your other hand fold up the adjacent panel to 90° then relax the fold flat again.
-
Repeat on the other side
Pin down the other side of the window panel and do the same thing there, folding on the crease line to 90° and unfold flat.
-
Continue pre-breaking side panels
Continue the pre-breaking process on the remaining side panels to ensure clean folds.
-
Complete side panel preparation
Finish preparing all side panels with proper pre-breaking for smooth assembly.
-
Fold front panel to 180°
Spin the box so the window is away from you and the sides are running perpendicular to your body. On the crease line that runs along the length of the front just outside the gussets, fold the panel over to the full 180° and unfold flat again.
-
Continue front panel folding
Complete the front panel folding process.
-
Finish front panel preparation
Complete the front panel preparation with proper creasing.
-
Fold gussets and panel to 90°
Working your way in to the next score line, use your fingers on the gussets again and fold the gussets and panel up to just past 90° and then back flat.
-
Continue gusset preparation
Continue the gusset preparation process.
-
Fold base score to 180°
Keep moving towards the window and fold the score for the bottom of the base all the way over 180° and then unfold the box flat again.
-
Complete base preparation
Complete the base preparation with proper folding.
-
Fold window-side score to 180°
Spin the box so the window is close to you. Fold at the score just outside the gussets to 180° and unfold flat.
-
Stand up lid side panels
Using both hands stand up the side panels of the lid till they form right angles.
-
Push in gusset center folds
Use your thumbs to push in on the center folds of the gussets to get things started.
-
Guide panel over gussets
While holding the sides open with your fingers, guide the panel up and over the gussets locking the foot of the panel in place with your fingertips. It is ok if the feet of the lid slide under the feet of the side panels. The lid will true-up once it is closed over the base.
-
Continue lid assembly
Continue the lid assembly process.
-
Secure lid panels
Secure the lid panels in their proper positions.
-
Complete lid structure
Complete the lid structure assembly.
-
Assemble the base
Spin the box so the base is closest to you. Do what you did on the lid. Erect the sides to right angles and use thumbs to fold the gussets in again and lock the foot of the panel against the feet of the side panels.
-
Continue base assembly
Continue the base assembly process.
-
Secure base structure
Secure the base structure in its final position.
-
Fold back flaps to 90°
In the back of the base, fold the back flaps in 90°.
-
Prepare for lid closure
It is easiest to close the lid if you first fold up that back panel to vertical so it is flat against the little flaps you just folded in the back.
-
Close the lid carefully
The walls of the lid are meant to hug the base so you may need to help them around the bottom of the box when closing the lid.
-
Guide lid walls around base
Continue guiding the lid walls around the base for proper closure.
-
Complete assembly - video tutorial available
Complete the one-piece simplex box assembly. Your box is now ready for use. If you are more of a video person, we put together a short movie showing how to set up your simplex box.
