Abstract: A hard-sided cooler is formed by extruding a flat sheet of material and die cutting the materials in a specific pattern which includes panels and various fold lines; the cooler being able to be shipped efficiently and economically in its flat configuration until it reaches the distribution point where the cooler is then transformed into the assembled configuration by folding the sheet of material along the manufactured fold lines, securing the edges of the material together and then adding insulation, a liner, a handle and a lid; the cooler optionally having graphics which may be applied to the show—side of the cooler body during the extrusion process or by way of graphic inserts or wraps.