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Box Dimensions: How to Determine Package Size
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Box Dimensions: How to Determine Package Size

Your product is finished and you’re ready to start selling, but there’s still one more step: what are you going to ship it in? There are lots of different box styles and sizes available. Thankfully, there are simple steps that make the entire packaging and shipping process seamless and easy.

Here’s everything you need to know about determining the perfect, custom-fit box for shipping your products.

Pick a Box Style for Your Product

Different items require different types of packaging. For example, heavy objects will likely need more durable packaging material like corrugated cardboard. Corrugated board has a folded middle layer that adds strength and protection, and it comes in different thicknesses.

Read more about choosing the appropriate cardboard thickness for your needs.

Fragile Items

Fragility is another important factor to consider. If any of your products are fragile, you’ll need to make special packaging considerations to ensure everything arrives in one piece. A thicker corrugated box is recommended in these cases.

Additionally, custom product inserts add an extra layer of protection during transit. 

How to Determine a Box and Package Size

Take Your Measurements

Now it’s time for the next step: measuring your products. Packaging a single product is easy. However, packaging multiple items in one box requires some experimentation to find the best layout.

Keep in mind that layouts create a first impression during unboxing. Think about what customers want to see and what will look aesthetically appealing.

When it comes to packaging measurements, dimensions always refer to the interior measurements of the box—this is the industry standard. If your products fit within those measurements, they’ll fit inside the box.

Record three measurements in inches:

  • Length (L): side to side
  • Width (W): front to back
  • Depth (D): top to bottom

It’s a good idea to add an extra 0.25 inches to your measurements for wiggle room, ensuring items aren’t crammed into the box.

Expert tip: Measure twice and keep these numbers handy for quick reference.

Weigh Your Product

Weight is another factor shipping companies use to calculate costs. Heavier packaging increases shipping expenses, so it’s important to balance strength and weight.

Weigh your items before choosing packaging. Consider investing in a reliable shipping scale to ensure accurate measurements across your product line.

Select the Right Box Size

Once you’ve gathered your measurements and product weight, the next step is to find a box that fits your needs.

Common Mailer Box Sizes

Dimensions (inches)

Ideal for Shipping:

4 x 4 x 2

Jewelry, small candles, USB drives, gift cards

6 x 6 x 2

Cosmetics, mugs, snacks, phone accessories

8 x 5 x 3

Stationery, small books, skincare sets, tech gadgets

8 x 6 x 4

Apparel accessories, multiple cosmetics, candles, gift sets

9 x 8 x 3

Journals, tablet cases, subscription boxes, and larger accessories

10 x 9 x 4

Clothing items, books, small electronics, bundled gifts

14 x 10 x 4

Shoes, apparel sets, larger gift bundles, premium subscription boxes


Common Shipping Box Sizes

Dimensions (inches)

Common Items That Fit

6 x 6 x 6

Coffee mugs, candles, small electronics, cosmetics

8 x 8 x 8

Books, small kitchenware, subscription boxes, apparel

10 x 10 x 8

Shoes, bulk snacks, electronics accessories, gift sets

12 x 12 x 6

Apparel, board games, books, bundled gifts

12 x 12 x 10

Sweatshirts, multiple books, larger electronics, toys

14 x 14 x 12

Bedding accessories, small appliances, bulk orders

16 x 14 x 14

Large clothing orders, kitchenware, home décor, sports gear

20 x 18 x 12

Large electronics, blankets, bulk products, multi-item shipments

These sizes are a starting point, but there are thousands of variations to fit your specific needs. Box Genie also creates custom-fit sizes beyond the dimensions listed here.

Mailer Boxes vs. Shipping Boxes

There are two main types of packaging used to ship products: mailer boxes and shipping boxes.

Mailer boxes are designed for direct mail and are favored for their self-locking designs and aesthetic appeal. They’re easy to assemble, provide a polished unboxing experience, and can be customized with your branding—making them popular with subscription services, eCommerce brands, and businesses seeking a premium look. 

Mailer Box Features:

  • Aesthetic appeal: Sleek and professional, they enhance brand value and the customer unboxing experience.
  • Durability: Strong and protective during transit.
  • Customization: Easy to print and tailor to your brand identity.
  • Eco-friendly options: Box Genie mailer boxes are made from recycled materials and are recyclable, appealing to eco-conscious customers.

Shipping boxes are the most common packaging type. They’re versatile, economical, and available in a wide variety of sizes and strengths—ideal for everything from lightweight goods to heavy items.

Shipping Box Features:

  • Versatility: Wide range of sizes to fit almost any product.
  • Cost-effectiveness: Generally less expensive than mailer boxes, great for tight budgets.
  • Variety: Available in different corrugated strengths to suit the weight and fragility of the products.

Packaging & Box Enhancements

Custom box dividers and product inserts elevate your packaging while protecting items during transit. Multi-compartment inserts are ideal for subscription boxes, kits, or bundles—keeping products in place and looking their best.

How to Find Length Width Depth of Custom Box

Custom Packaging

For many businesses, custom packaging is the best solution. It allows you to customize not only the size and style of the box but also the design and features.

Custom packaging strengthens your brand identity and creates a positive impression before customers even see the product. You can personalize color, text, and graphics so your box instantly communicates your brand when it arrives.

Investing in custom packaging helps your brand stand out in a sea of plain brown boxes—an investment that customers notice and that can increase revenue.

Designing Custom Packaging

When designing your packaging, keep these considerations in mind:

  • Your brand: Use consistent fonts, colors, patterns, and logos.
  • Your target customer: What packaging details matter most to them?
  • Your sales channel: Where will customers encounter your packaging, and will it stand out from competitors?
  • Your packaging partner: Work with experts, like Box Genie, who can guide you toward personalized solutions tailored to your business needs.

As you can see, figuring out your package size doesn’t have to be a chore. With a little planning, you can quickly choose the right box, arrange your products, and get them shipped in a way that delights your customers.

 


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