In today’s retail environment, cardboard displays have become an essential tool for capturing shopper attention and boosting sales at the point of purchase. Their lightweight structure, versatility, and cost efficiency make them ideal for product launches, promotions, and seasonal campaigns. But how are these displays actually made? Manufacturing Process of Cardboard Displays: From Design to Digital Printing
Creative Brief and Product Analysis
The process begins with gathering key information: product type, dimensions, weight, promotional message, and in-store placement. This step is crucial for defining the type of display needed, whether it’s a floor display, counter display, header, stopper, or any other format. The goal is to ensure that the display is not only visually appealing but also functional and durable.
Structural Design: The Engineering Behind Cardboard
Once the objective is clear, the structural design team develops a prototype focused on strength, ease of assembly, and material efficiency. Specialized software is used to create dielines, cuts, and folds, ensuring the structure can hold the product weight without bending or collapsing.
At this stage, designers determine:
- Type of cardboard (micro-flute, single wall, double wall)
- Assembly system (tabs, inserts, locks)
- Final dimensions optimized for shipping and display
Prototyping and Physical Testing
Before moving into production, a physical prototype is created to validate dimensions, stability, and appearance. This sample helps identify any structural adjustments needed and confirms that the display meets quality and resistance standards. Prototyping also allows for testing the ease of assembly in-store.
Graphic Design and Artwork Preparation
With the structure finalized, the graphic design team develops the visual identity—colors, images, promotional messages, and branding elements. During this stage, designers prepare the final artwork considering:
- Cut, fold, and glue areas
- Proper resolution for digital printing
- Brand color accuracy
- Visual adaptation to each face of the display
Effective graphic design transforms a functional display into a powerful visual marketing tool.
Digital Printing: Precision and High-Impact Graphics
Digital printing has transformed the cardboard display industry by enabling short runs, personalized campaigns, and faster turnaround times. In this phase:
- Sheets are printed directly onto the cardboard surface
- Photographic-quality graphics ensure vibrant colors and fine detail
- Production becomes flexible for regional or personalized campaigns
Thanks to this technology, brands can launch high-impact displays without the need for large minimum order quantities.
Die-Cutting, Laminating, and Finishing
After printing, the sheets are processed with die-cutting machines that create precise shapes, slots, and folds. Additional finishing options may include:
- Matte or gloss lamination
- UV coating
- Structural reinforcements
These finishes enhance durability and give the display a premium look.
Assembly and Packaging
Finally, all components are assembled manually or semi-automatically and packaged flat to optimize transportation. Many brands include assembly instructions to ensure a quick and tool-free setup at the point of sale.
Conclusion
The manufacturing process of cardboard displays blends creativity, engineering, and technology. From structural design to digital printing, each step is crafted to maximize brand visibility and create an impactful shopper experience. Choosing an experienced manufacturer ensures a display that is durable, visually striking, and effective in the highly competitive retail environment.
With Cyecsa / Kibox, you will have the peace of mind that you are working with a company that cares ecologically, socially, and economically.
If you want more information, connect with us via Kibot for a personalized consultation
