Selecting the correct box size is more important than you might think. A box that’s too big can lead to higher shipping costs and damaged items, while one that’s too small can result in crushed products and frustrated customers. At The Packaging World, we specialize in creating custom boxes that fit your products perfectly—because size matters in packaging.
In this guide, we’ll show you how to measure your products accurately so you can choose the ideal box size every time.
1. Understand the Three Key Dimensions
When measuring a product for packaging, focus on these three dimensions:
Length: The longest side of the product
Width: The shorter side (adjacent to the length)
Height (or Depth): How tall the item stands when it’s upright
Always measure in the order of length × width × height. These measurements are the foundation for determining the internal dimensions of your box.
2. Use the Right Tools
To ensure accuracy:
Use a measuring tape or ruler with millimeter or inch markings
Measure on a flat surface to avoid distortion
Double-check measurements, especially for irregularly shaped items
Tip: Round up to the nearest 1/4 inch to allow for slight product variations or extra padding.
3. Account for Protective Packaging
Don’t forget to include space for void fill or cushioning materials.
Depending on what you’re shipping, you might need to add:
0.5 to 1 inch for bubble wrap
1 to 2 inches for foam inserts or air pillows
Space for product inserts, brochures, or promo cards
By factoring in protective packaging, you ensure the final custom box will keep your product safe in transit.
4. Measure Odd-Shaped or Bundled Products
If your product isn’t a perfect rectangle, measure its widest and tallest points to determine the box size needed.
For bundled or multi-product sets:
Arrange the items the way they’ll be packed
Measure the combined dimensions
Consider dividers or custom inserts to keep everything secure
At The Packaging World, we can help design inserts and dividers that make your custom boxes more efficient and protective.
5. Consider Shipping Requirements
If you’re shipping via major carriers like USPS, FedEx, or UPS, your box’s dimensions can affect your rates.
Dimensional (DIM) weight pricing means larger boxes could cost more, even if they’re lightweight. Choosing a snug, custom-sized box helps:
Reduce shipping fees
Minimize packaging waste
Present a more professional unboxing experience
6. Test Before You Bulk Order
Before committing to a large run of custom boxes, test a few samples with your product:
Does it fit well without too much movement?
Is it easy to open and close?
Is there enough room for protective material?
If it checks all the boxes (literally), you’re ready to scale up your packaging with confidence.
Final Thoughts
Proper measurements lead to perfect packaging. Whether you're shipping clothing, electronics, or fragile items, starting with the right box size is key to protecting your products and saving money on logistics.
At The Packaging World, we make it easy to order custom boxes that fit your products perfectly. From measurement to design, we’re here to guide you every step of the way.
Contact us today to get a custom quote based on your product dimensions—and say goodbye to oversized, inefficient packaging for good.
