What is V-FORM packaging?

V-FORM is the latest innovation in luxury rigid boxes manufacturing, developed to transform how rigid boxes packaging can be engineered, constructed, and customised.

Exclusively by Progress, this revolutionary process works by scoring a V-shaped groove into heavy-weight board to enable a number of key benefits including sharp folds and seamless joins. V-FORM creates new opportunities to develop more distinctive designs for custom rigid boxes and luxury packaging boxes.

Whether you’re developing high end packaging boxes for premium cosmetics or luxury brand packaging for watches or fragrances, the V-FORM process enhances quality, reduces material use, and maximises creative potential. It’s the ideal method for brands looking to produce custom luxury boxes that stand out in both form and function.

More form, less fuss.

Traditional custom rigid box manufacturer methods, such as paper-over-board, often involve layering materials over greyboard. In contrast, V-FORM simplifies the production of rigid boxes by scoring directly into the board – enabling effortless folds, neat 90-degree angles, and elegant luxury rigid box finishes. This reduces the need for excessive layering, saving on materials and improving the environmental footprint – perfect for eco-friendly packaging solutions.

WHY CHOOSE V-FORM FOR YOUR RIGID BOXES PACKAGING?

REFINED DETAILS – GET SHARPER EDGES & CRISPER CORNERS.

The V-FORM process delivers sharper edges and crisper corners unmatched by standard production methods, making it ideal for luxury rigid boxes and custom luxury rigid boxes that require a premium finish. The method works best with materials around 1.4 – 2mm thick. When scored, the material can be two-way folded to make universal creases and also die-cut to create different packaging shapes.

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INNOVATIVE STRUCTURE – SCORE, FOLD & SHAPE IN NEW WAYS.

From angular formats to hinged-lid box styles, V-FORM allows you to craft rigid boxes in innovative shapes, enabling you to be more creative with structural engineering. It’s ideal for custom rigid packaging that needs to balance strength and design appeal. The process also enables creases, edges, and folds to become more of a feature by using duplexed boards and papers to create tactile and visually dynamic ‘colour-edge’ effects.

EFFICIENT, ECO-CONSCIOUS MANUFACTURE – USE LESS MATERIAL.

The single-sheet construction reduces waste, making V-FORM a perfect solution for sustainable rigid box manufacturing. The V-FORM process is also more efficient, as it provides the largest dieline area on a sheet – meaning formats can be maximised while material wastage is minimised. V-FORM formats can be constructed from a single sheet of material, preventing the need to cover, glue, and edge-wrap grey board.

CLEVER PACKAGING ENGINEERING – GET CREATIVE WITH MATERIALS.

When folded, glued, and finished, the V-FORM process makes structural engineering on luxury packaging boxes more precise – delivering seamless joins and a reductive aesthetic purity. Using the V-FORM process with either self-coloured duplexed boards or rigid boards with different coverings offers limitless freedom to use materials creatively, while making packaging more unique and distinctive.

V-FORM sample pack

Register your interest

As a luxury packaging manufacturer, we’ve developed the V-FORM sample pack as a hands-on tool to creatively demonstrate how this revolutionary production process can be used to transform the possibilities of your custom rigid packaging.

The pack will enable you to explore up-close the benefits, opportunities, and luxurious qualities that this versatile packaging manufacturing process presents. The packaging was designed by Design Project and produced using GF Smith Colorplan.

WHAT’S INCLUDED:

Fold-out packaging format with instructional inserts.
Samples of V-FORM production techniques.
Multiple coloured duplexed boards.
Dynamic ‘colour-edge’ examples.

MAKING DIFFERENT SHAPES OF LUXURY PACKAGING BOXES WITH V-FORM

The V-FORM manufacturing process works for any style or format of luxury packaging boxes. It’s an alternative to the paper-over-board process but with a number of added-value benefits.

Whether you’re looking to create a unique take on traditional luxury packaging boxes for cosmetics and skincare, high end packaging boxes for fashion accessories and apparel, custom rigid boxes for tech and electronics, rigid gift boxes for drinks, or luxury brand packaging that demands aesthetic and structural excellence, V-FORM can help transform the creativity, quality, and performance of your luxury packaging.

Curved boxes

The V-FORM process can be used to create fluid shapes on custom rigid boxes. Die-cutting softer outlines before gluing to form the overall format allows you to be more creative and precise with smooth, curved shapes.

Angular boxes

Angular custom rigid boxes are a natural fit for the V-FORM process due to the precision achievable when folding and gluing. Die-cutting and mitring surfaces together enables more challenging custom shapes to be easily developed.

Hinged-lid boxes

Hinged-lid custom rigid boxes are one of the most popular formats of luxury packaging. The V-FORM process offers additional customisation options by using materials to make a feature of edges and folds—giving a new twist to this classic format.

Card holders

Luxury card holders are an ideal format for the V-FORM process, as it allows folds and creases to be seamlessly mitred for a sharp, precise finish. This process unlocks endless possibilities for custom designer card holders, using material colours to highlight surfaces, edges, and folds as distinctive design features.

STEP-BY-STEP:
HOW V-FORM RIGID BOXES ARE MADE

Step 1
— Printing

Compatible with litho, foil-blocking, and digital methods, V-FORM supports vibrant rigid box printing and graphic precision. Depending on the graphics, sheets can either be litho printed before being laminated to a suitable rigid board or, for a more luxurious and tactile finish, sheets can be directly foil-blocked onto self-coloured boards.

Step 2
— V-cutting

To form each custom rigid box, a bespoke cutting tool creates a v-cut channel into rigid board, which is fed through the machine on a cylinder. To make unique packaging shapes, sheets are grooved at different angles.

Step 3
— Die-cutting

To make a custom rigid packaging dieline, printed sheets are pierced with a cutting form which penetrates through the board to create the outline shape.

Step 4
— Gluing & making

The v-cut is glued internally, enabling seamless 90-degree joins – making the process perfect for custom luxury boxes that demand clean lines and precise detailing.