Custom Cardboard Bike Box

Specifications & Customization Options – Designed to Fit, Built to Protect

Our cardboard bike boxes are engineered to accommodate road bikes, mountain bikes, folding bikes, and even electric bicycles. We provide flexible options for sizing, material grade, structural design, and visual branding to meet the demands of international shipping and retail distribution.

Customization Item	Available Options
Box Sizes	Standard: 1400×200×750mm / 1500×220×800mm / Custom dimensions based on bike geometry
Material Type	Corrugated Board: BC-flute / EB-flute / Triple Wall (for e-bikes or export)
Board Strength	ECT 44–61 (double wall), 350lb burst rating, optional reinforced edges
Structure Style	Full Overlap Slotted Carton (FOL), Die-Cut with Closure Tabs, Locking Flaps
Closure Options	Taping flaps / Slot-in tabs / Cable tie punch holes / Staples
Carry & Handling	Optional die-cut hand holes / Fork protector zones / Wheel & pedal compartments
Printing Capabilities	Flexographic (1–3 color logo), Digital (full side branding), Handling instructions
Surface Finish	Kraft brown (default), White liner, Recyclable matte coating (optional)
Labeling Zones	Pre-printed shipping label areas, barcodes, QR codes, “This Side Up” & “Fragile”
Certifications	FSC, RoHS, REACH, ISO 9001, Export packaging compliant
MOQ	Starting from 300–500 boxes per design

Additional features such as internal padding inserts, foam protection, fork guards, dropout spacers, and wheel dividers can be added upon request.

Structure & Style Design – Protection-Focused Box Designs for All Bicycle Types

Our cardboard bike boxes are available in multiple structural formats designed for ease of packing, transport efficiency, and maximum protection. Whether you’re shipping fully assembled bikes, partially disassembled models, or electric bicycles with sensitive components, we offer smart box structures tailored to your logistics strategy.

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1. Full Overlap Slotted Carton (FOL) – Heavy-Duty Export Structure

This format features extended flaps that completely overlap for enhanced edge and top panel strength. Ideal for export shipments and heavier bikes (e.g., mountain bikes, e-bikes).

Benefits:

• Excellent compression resistance during stacking
• Full surface coverage for impact absorption
• Compatible with strapping and stretch wrap for pallet shipments

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2. Die-Cut Locking Tab Box – No Tape Assembly

Designed for manual assembly without tools, this structure includes locking flaps, side tabs, and pre-scored fold lines—suitable for showroom packaging or DTC delivery.

Applications:

• Road bikes with quick-release wheels
• Custom folding bikes or OEM deliveries
• Consumer self-assembly kits

Features:

• Tool-free closure
• Clean edge presentation
• Optional integrated handle cutouts

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3. Top-Loading or Side-Loading Flap Box

Standard RSC (regular slotted carton) structure modified with extended flaps for easier insertion of large bike frames or accessory components like helmets or pedals.

Best for:

• Quick warehouse packing
• Lightweight bikes with partial disassembly
• Bulk shipping from assembly plants

Advantages:

• Compatible with automatic taping
• Optional foam inserts and divider channels
• Room for internal zip-tied components

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4. Fold-Flat, Self-Locking Bike Boxes

Ideal for space-efficient storage and flat-packed delivery, this format is pre-creased and folds into a sturdy structure without adhesives. Especially useful for packaging supply resellers and storage services.

Ideal For:

• Bike rental companies
• Subscription-based bike deliveries
• Emergency return or warranty packaging kits

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5. Integrated Insert Systems (Optional)

To enhance protection for specific parts or models, we can supply custom inserts as part of the box design.

Available Add-ons:

• Wheel separation channels
• Fork support and dropout spacer
• Seat post cushioning sleeve
• Frame anchor flaps or cable tie slots

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Each box structure is tested for dimensional stability, drop resistance, and load compression, and can be custom-matched to the specific frame style, wheel size, and shipping route.

Materials & Printing Options – High-Strength Corrugated Board with Customizable Surface Branding

Our cardboard bike boxes are built using reinforced corrugated materials specifically selected for their load-bearing, puncture-resistant, and crush-resistant properties, especially critical during freight handling and long-distance transit. We also provide high-clarity printing options for brand visibility and shipment compliance.

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1. Corrugated Board Options for Bicycle Protection

We offer a range of flute combinations and board strengths to suit the weight, frame design, and destination of the bike shipment.

Material Type	Thickness	Ideal Use Case
BC-Flute	~6mm	Medium-duty bikes, multi-unit warehouse shipping
EB-Flute	~4.5mm	Strong yet lighter option for retail-ready packaging
Triple Wall Board	~8–10mm	Heavy-duty shipping, e-bikes, high-risk freight conditions

Board Performance:

• ECT rating: 44–61, optionally up to 71 for international export
• Bursting strength: 275–350 lb
• Moisture resistance: Optional waterproof coating for sea/air shipping

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2. Eco-Compliant and Recyclable Materials

All packaging components are safe, sustainable, and meet global environmental requirements.

• FSC-certified paperboard
• RoHS & REACH compliant inks and adhesives
• AZO-free, formaldehyde-free raw materials
• 100% recyclable and biodegradable

For eco-conscious brands, we offer plastic-free packaging alternatives and carbon-reduced production plans.

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3. Surface Finishing & Protection Layers

While most bike boxes are kraft brown for practical shipping, we offer optional finishes to improve surface durability and visual clarity for branded deliveries.

Available Finishes:

• Kraft natural brown or white liner
• Matte water-resistant coating
• Anti-scuff or anti-abrasion varnish
• Optional UV spot or anti-scratch surface for retail presentation

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4. Functional & Branded Printing

Whether for identification, logistics compliance, or marketing, we help you print directly on your box surface with sharp, warehouse-safe ink.

Print Method	Purpose
Flexographic	Logos, handling marks, serial numbers, barcodes
Digital Printing	High-resolution logos, QR codes, multilingual instructions
Pre-printed liners	Seamless branding across large box surfaces

Standard Print Features:

• “This Side Up” arrows
• Fragile / Heavy warning icons
• Labeling zones for SKU or PO identification
• Retail-ready external brand display (optional)

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Whether you’re looking for maximum protection in transit or a refined branded presentation, our material and printing systems allow you to deliver bikes safely, professionally, and sustainably.

Application Scenarios – Trusted Bicycle Packaging for Global Transport and Retail Distribution

Our cardboard bike boxes are engineered to meet the packaging demands of bicycle manufacturers, exporters, online retailers, moving companies, and storage providers. Whether you’re shipping one bike or thousands, we help ensure that your bicycles arrive intact, protected, and professionally presented.

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1. OEM Bicycle Manufacturing & Global Export

Bike manufacturers rely on durable packaging to ship semi-assembled or fully assembled bicycles worldwide, especially in containerized or palletized loads.

Applications:

• Factory-to-retailer shipping
• Semi-knocked-down (SKD) bicycle export
• Contract manufacturing deliveries

Benefits:

• Custom-sized boxes for model-specific fit
• Triple-wall protection for sea freight
• Optional branding for OEM/ODM programs

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2. E-Commerce Bicycle Brands (DTC Shipping)

Direct-to-consumer bicycle brands need packaging that balances protective strength with a high-quality unboxing experience.

Ideal For:

• Road bikes, hybrid bikes, foldable bikes
• Subscription-based bike services
• Crowdfunded or startup brands

Features:

• Easy-open structure
• Interior padding integration
• External logo and instructional print

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3. Bike Retailer Delivery & Warehousing

Retailers and distributors use our boxes to manage bulk orders, warehouse-to-store transfers, and customer-specific shipments.

Use Cases:

• In-store assembly programs
• Warehouse inventory management
• Local delivery with courier handover

Operational Benefits:

• Label zones for SKU and PO
• Stackable and pallet-compatible dimensions
• Durable design for re-boxing or reverse logistics

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4. Bike Moving & Storage Services

Our boxes are also widely used by bike transportation companies or individual cyclists shipping bikes for relocation, competitions, or travel.

Common Scenarios:

• Air travel (check-in bike box)
• Relocation and moving services
• Event-based bike logistics (e.g., triathlon)

Box Features:

• Handle cutouts for lifting
• Internal wheel/seatpost protection options
• Labels for fragile and upright positioning

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5. Premium Bike Launches & Collector Editions

For luxury or limited-edition bikes, our customized packaging creates a branded unboxing experience while offering logistical safety.

Used By:

• Boutique bike brands
• Collector’s edition launches
• Influencer/PR deliveries

Key Features:

• High-end finishes with logo embossing or foil
• Insert trays for accessories or certificates
• Magnetic flaps or drawer-style enclosures (upon request)

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From container shipping and e-commerce fulfillment to event logistics and branded retail, our cardboard bike boxes deliver maximum protection, versatile structure, and scalable supply—ensuring your bicycles arrive in perfect condition, anywhere in the world.

Customization Services & Packing Specifications – Precision Packaging, Built Around Your Bicycle and Brand

We offer comprehensive customization services for cardboard bike boxes tailored to your product specifications, logistics needs, and brand image. Whether you’re a bike manufacturer, international distributor, or e-commerce brand, we help you design and deliver protective, presentation-ready packaging on a global scale.

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OEM / ODM Design & Manufacturing

We support both OEM (your design, our production) and ODM (we design to your product) services:

• Custom box dimensions based on bike frame geometry
• Engineering support for box strength, insert layout, and shipping mode
• Multi-size packaging systems (e.g., 26”, 27.5”, 29”, folding, e-bike)

Optional Engineering Add-ons:

• Inner buffer spacers (foam or corrugated)
• Fork protectors, dropout guards, wheel sleeves
• Divider trays and accessory pockets

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Branding & Labeling Options

Your cardboard bike boxes can become part of your brand’s delivery experience. We offer professional-grade print and labeling support for retail and logistics.

• Flexo or digital printing on all outer panels
• Pre-applied shipping marks, QR codes, barcodes
• Handling instructions: “This Side Up,” “Fragile,” “Do Not Stack”
• Branded flaps or interior print messages

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Packing Formats & Delivery Specifications

Boxes are optimized for space efficiency and shipping protection, with packing services aligned to your warehousing and distribution needs.

Packing Options:

• Flat-packed delivery for warehouse storage or assembly lines
• Pre-folded assembly (limited use, on request)
• Bulk-packed by size or model
• Kits with accessories, inserts, manuals included

Carton & Export Details:

• Palletization plans for FCL/LCL containers
• Outer carton labeling (box model, destination, PO)
• Custom HS code alignment and shipping documentation

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Export & Global Delivery Support

We offer international trade and logistics services, including full documentation and multi-modal shipping options.

• Trade terms: EXW, FOB, CIF, DDP supported
• Documentation: Packing List, Invoice, CO (Certificate of Origin), MSDS (if inserts used)
• Logistics: Coordination with forwarders, warehouse drop-ship, courier for samples
• Europe, North America, Asia, and Middle East shipping experience

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Production Lead Time & Order Volume

• MOQ: Starting from 300–500 units per model/size
• Samples: 3–5 days (plain); 7–10 days (printed prototype)
• Mass Production: 15–30 working days depending on complexity and volume
• Kitting Service: Available for boxed bike + accessory bundles

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Whether you’re developing packaging for a single new model or an entire global bicycle lineup, we help you create functional, professional, and scalable bike shipping boxes—from concept to container.

Key Advantages & Technical Features – Complete Protection and Professional Delivery for Every Bicycle

Our cardboard bike boxes are designed to deliver maximum structural performance, logistics compatibility, and brand visibility. Whether your bikes are heading to retailers, customers, or race events, these boxes offer a dependable and professional packaging solution.

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1. Reinforced Structural Integrity for Heavy and Large Items

We use multi-layered corrugated board with high edge crush and burst strength to protect full-size bicycles and e-bikes under demanding shipping conditions.

• Supports weights up to 30–50 kg
• Resistant to crushing, punctures, and bending
• Reinforced edges and full-overlap flaps available

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2. Frame-Fitting Precision for Multiple Bicycle Types

Boxes are tailored to accommodate specific frame sizes, wheel sets, and accessories, reducing the risk of internal shifting or damage during transit.

• Fit-tested with MTB, road bikes, foldables, and e-bikes
• Custom inserts and internal blocking for secure placement
• Minimized void space reduces movement-related damage

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3. Optimized for Warehousing, Handling & Transport

Designed for palletization and container loading, our bike boxes ensure storage efficiency and secure stacking.

• Flat-packed to save inbound freight and warehouse space
• Compatible with forklifts, conveyors, and standard pallet sizes
• Lightweight structure reduces volumetric weight for air shipping

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4. Logistics-Ready Labeling and Compliance

Boxes are equipped with label zones, directional icons, and handling instructions to facilitate safer, more organized shipping.

• “This Side Up,” “Do Not Drop,” and “Handle With Care”
• QR/barcode zones for automated warehouse systems
• Retail-ready print and customizable artwork positions

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5. Brand Presentation and Custom Print Integration

Beyond protection, our boxes support your branding goals through clean layouts, logo visibility, and consistent design language.

• Digital or flexo printing on large exterior surfaces
• Multi-language messaging for international markets
• High-quality finishes enhance customer perception on delivery

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6. Eco-Friendly and Globally Compliant

All materials are FSC-certified, fully recyclable, and tested for environmental and export safety.

• RoHS and REACH compliant
• Low-VOC inks, AZO-free adhesives
• Plastic-free internal solutions available for sustainable packaging programs

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Whether you’re packaging one premium bike or shipping full container loads, our cardboard bike boxes combine technical precision with operational reliability to protect your product and reinforce your brand—every step of the way.

Frequently Asked Questions (FAQ)

Q1: What is your minimum order quantity (MOQ)?
Our MOQ for cardboard bike boxes typically starts at 300 to 500 units per size/design, depending on the structure, print complexity, and use of inserts.

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Q2: Can I get a sample before placing a bulk order?
Yes. We offer:

• Plain white samples for size and structure testing: 3–5 working days
• Custom printed samples with branding and inserts: 7–10 working days

Shipping for samples can be arranged via express courier.

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Q3: What bicycle sizes can your boxes accommodate?
We customize boxes for:

• Road bikes, mountain bikes, BMX, foldables
• 26”, 27.5”, 29”, or e-bike formats
• Standard and oversized frame geometries

Let us know your bike’s dimensions or model, and we’ll adjust accordingly.

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Q4: Are the boxes strong enough for air or sea freight?
Yes. We provide:

• Double-wall or triple-wall board for heavy or sensitive bikes
• Bursting strength up to 350 lb
• Moisture-resistant coatings for sea shipment
• Drop and compression testing support (optional)

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Q5: Can you print logos or handling instructions on the box?
Absolutely. We support:

• Flexographic printing (1–3 color) or full-panel digital branding
• “Fragile,” “This Side Up,” “Do Not Stack” icons
• Custom label and barcode areas
• Inner print messaging for unboxing experience (optional)

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Q6: Are your materials environmentally friendly and export-compliant?
Yes. All boxes are:

• Made from FSC-certified, recyclable materials
• RoHS/REACH compliant
• Free from AZO dyes, formaldehyde, and toxic coatings
• Suitable for Amazon, EU, North America, and Middle East shipments

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Q7: How are the boxes shipped?
Boxes are delivered:

• Flat-packed in master cartons or strapped bundles
• Palletized for sea or air freight
• With optional kitting (box + inserts + accessories)

Shipping marks, HS codes, and destination labeling are applied as requested.

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Q8: What’s the lead time for production and delivery?

• Samples: 3–10 working days depending on print
• Mass production: 15–30 working days
• Shipping time: Based on destination; we support EXW, FOB, CIF, DDP

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Q9: Can you help us develop a custom insert or internal protection system?
Yes. We design and supply:

• Foam, paperboard, or corrugated inserts
• Fork spacers, dropout guards, pedal & wheel compartments
• Custom packaging kits with manuals or accessories

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Q10: Do you provide support for retailers, fulfillment centers, or bike brands?
Yes. We work with:

• Bike manufacturers (OEM/ODM)
• Global retailers and cycling brands
• Fulfillment hubs and distributors

We offer full B2B service with documentation, custom branding, and logistics coordination.