Custom Sample Sachets
A sample sachet is a single dose of something viscous in a package the size of a business card. It has to open cleanly with one hand, dispense completely, and lie flat enough to travel inside another pack.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the flat pouch / 3-side seal structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures sample sachets actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
Viscosity decides whether the sachet will empty at all
A thin lotion runs out of a torn corner; a thick balm stays in the corners of a flat sachet no matter how hard it is squeezed. For viscous products either use a stick so the product can be pushed along a tube, or add a rounded internal corner profile so there is nowhere for it to hide. Test with the real formula, not with a stand-in.
The mistake that costs a print run
Assuming the tear notch will be where you drew it
A notch has a tolerance, and a sachet torn slightly off line opens across the corner instead of the top. Put the notch on a straight seal edge with clearance either side, keep the artwork tolerant of a tear a few millimetres in either direction, and never place required copy where a normal tear will remove it.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom sample sachets
How small can a sample sachet be?
Around 2 × 2.4in is the practical floor for a converted flat pouch. Below that the format changes to sachet-machine tooling with a different set of constraints.
Will a thick cream come out of a flat sachet?
Often not completely. Viscous formulas trap in the sealed corners; a stick pack or a sachet with a wider opening empties far better, and it is worth testing with your real formula before committing.
Can sample sachets go inside a retail carton?
Yes, and it is one of the best uses for them. Keep the sachet's flat dimensions well inside the carton's internal size so it does not force the panels apart when the carton is closed.