Abstract: Methods for making multi-walled containers from a single blank, preferably using a continuous process approach, and the resulting containers are disclosed. Various embodiments of the invention include, alone or in combination, intermediate panels formed from flap precursors that are in- or out-folded such that their distal ends are in proximate relationship to each other; outer flaps sized to overlap exposed edges of a container formed from the blank; stress relief features a joint corners to reduce stresses thereat. Methods for making select containers of the invention include folding and adhering the flap precursors to an inner panel, up-folding the inner panel/intermediate panel combination about a mandrel, and continuing to up-fold the outer panel until a container having a “use” position as a resting position is formed.

Abstract: Methods for making multi-walled containers from a single blank, preferably using a continuous process approach, and the resulting containers are disclosed. Various embodiments of the invention include, alone or in combination, intermediate panels formed from flap precursors that are in- or out-folded such that their distal ends are in proximate relationship to each other; outer flaps sized to overlap exposed edges of a container formed from the blank; stress relief features a joint corners to reduce stresses thereat. Methods for making select containers of the invention include folding and adhering the flap precursors to an inner panel, up-folding the inner panel/intermediate panel combination about a mandrel, and continuing to up-fold the outer panel until a container having a “use” position as a resting position is formed.