This is a past manufacturing project showcased for reference only. All artwork and intellectual property belong to the original creator and are not available for retail sale.

This 450-card early learning set demonstrates advanced structural engineering for high-volume educational kits.

Covering a massive curriculum—including animals, foods, fruits, vegetables, and drinks—this project required a highly durable packaging solution.

76 mm x 76 mm (3″ x 3″)

For publishers planning custom flash card printing, managing physical weight and user experience is the ultimate challenge.

Housing 450 heavy-stock cards in a single oversized box causes structural instability and high transit damage rates.

The Engineered Solution: We manufactured a nested three-piece rigid box configuration, securely housed within a unified kraft master carton.

Exact Manufacturing Specifications

The Flashcards (450 Cards Total)

• Dimensions: 76 mm x 76 mm (3″ x 3″)
• Material: 350gsm Premium Art Paper
  • Technical Detail: High-density stock providing excellent snap and shape retention for repeated handling.
• Print & Finish: CMYK Full Color + Matte Lamination
  • Technical Detail: Anti-glare finish ensures high legibility under classroom lighting and superior scuff resistance.

The Inner Packaging (Lid-Bottom Rigid Boxes)

• Capacity: Precision-engineered to hold exactly 150 cards per box.
• Material: 157g Art Paper wrapped over 1200g Gray Cardboard.
  • Technical Detail: Delivers high crush resistance, preventing board warping under the dense cardstock’s weight.
• Finish: Matte Lamination.

The Master Outer Carton

• Style: Custom Eco-Friendly Kraft Paper Box.
• Function: Serves as a master slipcase and transit-ready enclosure, unifying the three rigid components into a single bundle.

Craftsmanship & Structural Engineering

Close-up of the 3 rigid boxes fitting into the kraft box

Feature: Nested Multi-Box Architecture

• The Benefit: Distributes the massive payload of 450 cards evenly.
• This prevents packaging blowouts during international freight and offers a highly organized unboxing experience.
• It also allows end-users to interact with one specific curriculum module at a time.

350gsm Art Paper / Matte Lamination

Feature: 350gsm Art Paper + Matte Lamination

• The Benefit: Delivers a tactile, premium feel.
• The matte film acts as a protective barrier, shielding the printed ink from moisture, natural skin oils, and friction.

Factory Note: Engineering Nested Box Sets

When manufacturing a nested set (like three rigid boxes inside a master kraft carton), you cannot simply add up the raw sizes of the inner boxes.

An experienced production team must account for the caliper buildup added by the 157g wrapping paper, the lamination film, and the natural expansion of the 1200g gray board.

We calibrate our die-lines with a precise tolerance gap (typically 1.5mm – 2mm).

This ensures the inner boxes slide out smoothly without creating a frustrating vacuum effect, while remaining snug enough to prevent corner damage during palletized shipping.

Use This Specification as a Reference

This entire configuration is fully customizable.

Use this exact 3-piece box set architecture as a reliable baseline for your next multi-deck educational project.

Alternatively, have our engineering team develop a custom structural template tailored to your specific card count and material requirements.