Do you want the end customer to see part of the product without opening the box, or do you need a housing shape on an insert? On Packly you can edit the dieline generated online by adding windows (cut only, no plastic), cutouts and other small shape variations, directly while configuring your project.

This article explains how to add the element when ordering, how to set it up correctly in your artwork file, and which minimum distances to respect to avoid production issues.

Please note: on Packly, a "window" is always and only a cutout. There is no option to apply a transparent plastic film: our 100% paper-based packaging excludes any plastic lamination."

How to add the element when ordering

The change fits into the normal project creation workflow, before completing the order:

  • Configure the box: choose the model, enter the dimensions and select the desired material.
  • Download the dieline generated for your specific project (selected dimensions and material).
  • Open the file in vector graphics software (e.g. Adobe Illustrator).
  • Draw the shape of the window or cutout over the dieline, following the instructions in the next section.
  • Save the file and upload it again on the project creation page on Packly.
  • Check the result in the 3D preview: the change is visible immediately. If everything is correct, proceed with the order.
  • You can add up to 9 elements in total, including cutouts, windows, custom fold lines and perforations. If your project requires more than 9 elements, or a dieline completely different from those offered by Packly, send your file to [email protected]: the team will check feasibility and guide you through the project.

How to set up the cutout in the file

For the system to correctly recognise the cutout, the shape must not be drawn as a simple graphic object: it needs to be created with a dedicated spot colour.

  • Create a new spot colour and rename it exactly Custom-Cut (respect capitalisation and hyphen).
  • Use the colour at 100% coverage.
  • In the Swatches panel, set Color Type > Spot Color.
  • Enable the Overprint attribute on all the dieline's lines, including the ones you have just added.
  • Keep the dieline and the artwork on two separate layers; delete any layers containing elements that are not visible or that must not be printed.
  • Save the file in CMYK mode, as Adobe® PDF "Press Quality".
  • To see the actual opening in the 3D preview (not just the outline), set the Custom-Cut colour as the shape's fill, not only as its stroke: the fill creates a real opening, while the stroke only shows the outline without "piercing" the 3D model.

Please note:

These settings are needed to achieve correct 3D visualisation. During physical production, the cutout piece may not separate completely on its own (small retaining points can remain, especially on complex or very narrow shapes): an aspect to consider already at the artwork design stage, especially if the cutout needs to "fall out" on its own.

If you also add custom fold or perforation lines in the same file, use the spot colours Custom-Crease and Custom-Perf respectively (same logic: 100% coverage, spot colour type).

Minimum distances and precautions

The minimum distances vary depending on the chosen material. The reference values are:

Material: Cardboard

  • Minimum distance from the dieline: 10mm
  • Minimum distance from the bottom: 15mm
  • Minimum distance between two cutouts: 10mm
  • Maximum surface of the added cutout: no more than 50% of the reference face

Material: Corrugated cardboard

Minimum distance from the dieline: 15mm

Minimum distance from the bottom: 25mm

Minimum distance between two cutouts: 15 mm

Maximum surface of the added cutout: no more than 50% of the reference face"

Other precautions to respect, valid for any material:

Do not move, modify or delete any original dieline line: the change must be added, not overlapped onto existing elements.

Do not position the cutout too close to text, logos or graphic elements that require precise alignment: cutting tolerance can create minor shifts.

On some packaging types (for example rigid boxes and boxes with side crease lines, such as Bag-in-Box or lid boxes), the cutout must stay within the dedicated "Cutout area" shown on the dieline: in particular, avoid areas near cut/fold lines, frames, edges or other elements that require precise alignment.

Always check the specific guide downloaded together with your dieline, as the values may vary slightly between product ranges.

The design lines (outlines, details) must have a minimum thickness of 0.3pt (0.1mm).