CPI.Custom Packaging Insights
BOX BASICS · PACKAGING BUYING GUIDE

Custom Box Sizes Explained

Measure your product and plan the perfect fit. A practical guide to making an informed choice and having a useful supplier conversation.

Key takeaways

  • Measure the product in its packed orientation, including accessories and protective materials.
  • Specify internal or external dimensions clearly and label every measurement with its unit.
  • Allow for inserts and cushioning, then confirm fit with a physical sample.
Illustrative assortment of packaging structures and materials

Measure the product first

Measure the product in the orientation it will occupy inside the box. Include caps, protrusions and any protective wrapping. For multiple items, arrange them together before taking measurements.

Internal versus external dimensions

Internal dimensions describe usable space; external dimensions include the structure and board thickness. Suppliers may use different dimension conventions, so confirm that your brief and dieline use the same definition.

Length, width and depth

Write every measurement with a unit and label it. A common convention is length × width × depth, but do not rely on the order alone. Provide a drawing or product photo when orientation is ambiguous.

Allow space for protection

Inserts, dividers and cushioning need room. Too much empty space can let products move, while too little can make assembly difficult or put stress on the product. Confirm tolerances and fit through a physical sample.

Check the shipping package

A retail carton and its shipping box are different design decisions. Ask for the external packed size and weight when estimating freight. Confirm packing arrangements with the supplier before production.

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