BUYER GUIDES

Custom Shipping Box Sizes: A Dimensions Guide for Every Product

Box size is where most first-time buyers lose money. Too big and you pay dimensional weight on air and buy void fill to stop rattle; too tight and the box fails or the product bruises. Getting the internal dimensions right is the highest-leverage decision in the whole spec.

How to measure

Measure your product’s length, width, and height at its widest points. Add clearance for protection — a little for a rigid item, more for something fragile that needs cushioning. Box dimensions always refer to internal size; tell us the inside and we handle the board thickness.

Product type	Suggested clearance	Notes
Rigid, durable	1/8–1/4 in each side	Minimal void fill
Semi-fragile	1/2 in each side	Light cushioning
Fragile / glass	1–2 in + insert	Molded or die-cut insert
Apparel (soft)	Snug, flat	Prioritize footprint over depth

Watch the dimensional weight

Carriers bill the greater of actual and dimensional weight. Shaving an inch off each dimension of a lightweight parcel can drop it a billing tier. A custom die that matches your product is the cleanest way to stop paying to ship air on every order.

Choosing for your order

Not sure what size you need? Send your product dimensions and we will recommend an internal box size and quote a custom die that fits it.