Full Flat Double Try Boxes
A full-flat double-tray structure that lays open for dual-compartment packing and reveal.
Structural & Engineering Details
How This Structure Works
This full-flat double-tray structure opens out flat to reveal two seated compartments, presenting dual sets of contents side by side. Laying open rather than lifting a lid, the geometry gives a broad, book-like reveal where both trays are visible at once. It can suit paired products, kits, or gift sets where showing two elements together matters. The flat-opening form also makes loading each tray straightforward before the box folds closed for transit. Because the two trays are part of one connected structure, there is no separate insert to align, and the reveal feels considered as both compartments come into view together.
Good Fit For
- Paired products and kits
- Gift sets shown two-up
- Presentations with dual compartments
Key Advantages
- Opens flat for a two-tray reveal
- Both compartments visible at once
- Connected trays need no separate insert
Assembly & Construction
The blank scores so the structure folds into two connected trays that lay open flat and then fold together to close, with a tuck, flap, or wrap holding the closed form. Each tray is seated within the same blank, so loading fills both compartments before the box folds shut. Assemblers form the trays, load each side, and close the structure, so the two-up reveal comes from the folding geometry rather than added inserts.
Materials & Board Options
A firm paperboard often suits double-tray structures where crisp folds and a clean reveal matter, and a rigid or wrapped board can lift the feel on premium versions. Final caliper, any wrap, and coating typically depend on the contents weight, box size, print finish, filling method, and handling, so a physical mock-up of both trays usually confirms the fit and the reveal.
Pre-Production Planning Checklist
- Confirm both trays seat their contents when opened flat
- Check the closure holds the folded structure shut
- Verify fold registration keeps the two-up reveal aligned
