How to Fold a Hexagon Box: Template, Measurements and Assembly Steps

A hexagon box looks complicated but is actually one shape – a base with six sides and six side panels which fold up from the edges. You will find it quick to assemble once you have the template and the measurements. In this post you will learn the formula for the size, the template diagram, how to fold, and what to do to fix any problems.

What You Need Before You Begin

Hexagon Box Size

Equal sided hexagons Regular hexagons have six equal sides and six 120°, or interior, angles. An equal sided hexagon starts with a chosen side length and work from this to find all other dimensions.

• Measuring from the corners (widest part) = side length x 2
• Parallel sides (across flats) = side length x 1.732

Set the height of the panels to the depth of the product. Set the width of the panels to the base side length, not the corners will not line up.

Constructing the Sample

1. The Base

Construct the hexagon using the length of side. If you do not have a protractor then construct the length of side using a pair of compasses, draw a circle, and step around the circle six times to mark the corners.

2. The Side Panels

Cut a rectangle out of the six bottom edges (width is that edge, height is box depth). Make those shapes all one continuous shape with the fold lines aligned along the bottom edges.

3. The Glue Tab

A thin strip, 10-12 mm wide, is glued to an edge of each side panel. The ends are cut to taper slightly so that the panel does not hang up on the next one.

4. The Lid

Make the lid in the same way, except do it one size bigger than the bottom. Generally a few mm is added to each side (say 1 or 2mm but check for yourself as it all depends on board thickness).

Step-by-Step Assembly

1. Discard the paper template and use only the outside lines.
2. Press lightly but evenly on each fold line to score. Scoring lines helps avoid cracked edges and ensures your creases are sharp and clean.
3. Fold all six panels out of the way at base edges, creasing well.
4. Apply glue or tape to the tab.
5. Connect the tab to the other side panel, then fold the inside seam for 10-15 seconds.
6. Check the corners. Make sure all six settle flush and there are no gaps.
7. Repeat for the lid.
8. Test the fit. The lid should fit easily with minimal force.

Frequent Issues and Solutions

When to Move From DIY to Custom Hexagon Boxes

If you are folding your own box, this is a great option for handmade projects, small gift runs and prototypes. It is not as practical if you need identical packaging, printed branding or larger batches. That is where custom hexagon boxes with die-cut tooling help, giving you identical panels, scored corners and a printed finish without the effort of hand assembly. If you start with a handmade prototype, you can pass its dimensions on to your supplier.

Neater Finish Tips

• Cut a test version out of scrap paper before you get to your good board.
• Edge your paper along the same grain direction as the folds for a sharper crease.
• Use a metal ruler to cut for a straight edge.
• You can add marks to the outside and the inside of the template so that printed or detailed sides are accurate.

Conclusion

Fold your hexagon box easily: Equal sides, angles of 120° and sharp scores. Work from the table of measurements, build your template from one joined shape and test the lid before you do any more. If you need to produce masses, use your prototype as a sample for a supplier.

Frequently Asked Questions

What angle do I need for a hexagon box?

Regular hexagon interior angle is 120° so if you take that as a basis, the six sides stay equal.

Which paper weight is best?

The majority of small boxes can be made from a cardstock/ light paperboard (200-300 gms/sm), although thicker board will need deeper scoring.

How do I get the lid to close?

Construct the lid slightly larger than the base, and test it. The fit can be adjusted as desired-a little nibble here and there makes a big difference, since you’ll need the exact amount of space for whatever material is used for your build.

Is it possible to fold a hexagon box without template?

Yup, but it takes a while to set up and gaffing is variable. Another net worked up for a one off without being connected.

How is a hexagon box measured?

Widest point- multiple side by 2. Flat side to flat side- multiple side by 1.732