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Manufacturing

Bespoke Wooden Boxes Manufactured to Perfection

At Polmac (UK) Ltd, we specialise in the manufacture of bespoke wooden boxes, offering fully customised solutions for luxury gift boxes, product packaging, and presentation cases. Combining traditional craftsmanship with semi-automated production methods, we create unique wooden boxes that meet your exact specifications!

The Polmac Manufacturing Team
The Polmac Manufacturing Team

Premium Wood Types for Exceptional Wooden Boxes

Our bespoke wooden boxes are crafted using carefully selected natural woods. We primarily use Linden wood, Alder wood, and Pinewood, known for their fine grain and smooth finish.

We also offer premium imported hardwoods for clients seeking a more distinctive, high-end look and/or finish.

Sustainable Timber, Naturally Seasoned

All timber used in our wooden box manufacturing process is sourced from sustainable and managed forests.

We procure rough-hewn planks directly from sawmills and naturally season them for up to two and a half years. This air-drying method ensures that the wood retains its strength and resists warping!

Where necessary, kiln drying is used to achieve the ideal moisture content, ensuring that every bespoke wooden box we produce is structurally sound and built to last!

planks of wood with a wooden wheel  depicting air dried timber
Air Drying a Timber Stack

Custom Wooden Box Production Process

Once the wood is seasoned, we begin production by shaping the timber into 8–10mm panels. These panels are carefully jointed and glued in precision mitring presses to form the basic wooden box shape. Each box lid is expertly cut using a circular saw, ensuring a perfect fit!

man sawing a wooden plank
Shaping a Wooden Plank
man in a white suit lacquer spraying a wooden crate
Lacquer Spraying Wooden Box
man holding a drill driver attaching a metal clasp to a box
Fixing a Metal Clasp

To enhance functionality and style, we incorporate v-groove joints and discreet vertical slots for concealed metal hinges. These are designed to allow lids to open to a full 90-degree angle. We also offer recessed, surface-mounted, and stop hinges depending on your design preferences.

Finishing & Decoration of Your Bespoke Wooden Box

After construction, your custom wooden boxes are fine sanded for a smooth finish. From there, they are taken to one of our spray booths for:

  • Natural wood and colour stain finishes
  • Vibrant primary and pastel colour finishes
  • Clear lacquer coatings

For more personalised touches, boxes can be hand-painted, carved, or decorated with pyrography. These specialised finishes give each gift box a truly distinctive, artisanal appearance, that attract more customers!

Final Assembly and Quality Touches

Once painted or stained, each wooden box is dried thoroughly before we hand-finish the inside edges. We then add high-quality fittings such as metal hinges, catches, handles, and stays.

If your design includes fabric lining, we carefully fit silk, flock, or hessian linings onto custom moulded inserts in both the lid and base of the box. To finish, we can apply logos, branding, or custom text, making each bespoke wooden box visually stunning and truly unique!

Strict Quality Control

Polmac is dedicated to delivering consistently high standards. Every bespoke wooden box undergoes rigorous quality control inspections before shipping.

Each box is wrapped in protective white paper, packed in five-layer, impact-resistant cartons, and shrink-wrapped on pallets for safe transportation.

man wearing a blue checked shirt inspecting a wooden box on a table
Final Inspection

Get in Touch for Custom Wooden Box Solutions

Looking for expertly crafted bespoke wooden boxes or high-quality wooden gift boxes? Whether you're launching a product, planning a promotion, or need personalised gift boxes, we’re here to help.

  • Call us today on +44 (0) 1494 533 857
  • Email us at This email address is being protected from spambots. You need JavaScript enabled to view it.

Can't Find What You’re Looking For?

If our website or blog doesn’t show exactly what you need, contact us at any time. We’ll gladly discuss your ideas and work with you to create a custom wooden box design that exceeds your expectations!