Overlap slotted box
Flaps overlap partly. Middle ground between RSC and full overlap.
- Example size
- 300 × 200 × 150 mm internal
- Blank
- 1041 × 378 mm
- Pieces
- 1 blank
- Board choices
- 12 boards, 0.45 to 7 mm
Free to design and to check in 3D. €2.50 for the PDF, €3.50 for the DXF or SVG.
What this box is, in other words
A shipping box for long, narrow contents. The outer flaps overlap, so the closure can be stapled or glued through two layers of board.
How it closes. All flaps are cut the same length. The inner flaps fold in first, then the outer flaps lie over each other by the overlap you set, 25 mm by default. Glue, tape or staples go through the overlap.
Worth knowing. The blank is taller than an RSC blank by the overlap plus the flap gap. On a box that is nearly square the inner flaps would collide, so the generator shortens them and says so in the notes.
Also called
OSC overlap slotted container overlap box shipping carton long box cardboard box overlap osc
Same construction, different trade. If you came looking for one of those, this is it.
How this one is built
- Overlap Slotted (FEFCO 0202): the outer flaps overlap by 25 mm. Close with glue, tape or staples through the overlap.
- Slot width = 1.90 mm (caliper plus clearance). Any narrower and the corner tears when folded.
- Glue flap 35 mm on long wall 1; glue it to the inside of end wall 2.
- Flutes run vertically, along the height: maximum stacking strength.
Board options
The drawing changes when you change the board: thickness compensation is built into every fold, so a 4 mm C-flute blank is not the same shape as a 0.45 mm carton blank.
- F-flute corrugated (0.8 mm)
- E-flute corrugated (1.5 mm)
- B-flute corrugated (3.0 mm)
- C-flute corrugated (4.0 mm)
- EB double wall (4.5 mm)
- BC double wall (7.0 mm)
- SBS / GC1 board 350 gsm (0.45 mm)
- FBB / GC2 board 400 gsm (0.55 mm)
- Kraft / GD2 board 400 gsm (0.50 mm)
- Greyboard 1.0 mm (rigid)
- Prototype board 1.0 mm
- Prototype board 2.0 mm
Questions about this box
- What is FEFCO 0202?
- An overlap slotted container (OSC). It is an 0201 with longer flaps: all flaps have the same length, and the outer flaps overlap instead of meeting in the middle. Box makers usually overlap them by 25 mm (one inch) or more.
- What is the difference between 0201, 0202 and 0203?
- How far the flaps overlap. In an 0201 they meet in the middle. In an 0202 they overlap partly. In an 0203 (full overlap) the outer flaps reach all the way across, which doubles the board on the base and is what you want under something heavy.
- How do I work out the blank size of an overlap slotted box?
- For internal size L x W x H and board caliper t: blank length 2L + 2W + 4t plus the glue flap, blank height H + W + 2t plus the overlap. The derivation and a calculator are on the FEFCO 0202 page.
- Is this dieline free?
- Designing it and folding it in 3D are free and need no account. Downloading it is paid: €2.50 for the PDF to print and measure on paper, and €3.50 for a production file - DXF or SVG - because those are the ones that go to a cutting table.
- What is a dieline?
- The flat drawing a box is cut from. It shows where the knife cuts, where the board is creased to fold, and where it is perforated. A die maker turns it into a steel rule die; a plotter or laser cuts it directly. It is also written as "die line" or "die cut template".
- What file format does a die maker need?
- DXF, almost always. Ours is R12 DXF at 1:1 in millimetres with cut, crease, reverse crease and perforation each on their own layer, which is what a cutting table expects. The SVG is the same geometry for Illustrator, Affinity, Inkscape and laser software.
- Can I use it commercially?
- Yes. The files are yours: modify them, print them, make any number of boxes from them. No attribution and no licence fee, ever.
What you can change
7 parameters on the first screen, 6 more behind advanced settings.
- Dimension mode
- Length (L)
- Width (W)
- Height (H)
- Board caliper (t)
- Variant
- Flap overlap — Overlap slotted (0202) only: how far the outer flaps overlap. Common practice is 25 mm (one inch) or more.