Determining dimensions is the first step in packaging design. When planning your packaging, simply provide the product dimensions, quantity, and whether an insert is required; we will calculate the appropriate box style and insert dimensions for you right from the start.
First, distinguish between internal and external dimensions. Internal dimensions refer to the space inside the box, determining whether the product fits; external dimensions refer to the overall size of the finished box, determining how it is packed and shipped. Always clarify which type you are specifying when communicating with the manufacturer; simply saying “dimensions” often leads to misunderstandings.
Dimensions are a common source of errors when ordering packaging. Product dimensions and box dimensions are not the same thing; a measurement error of just a few millimeters can result in an insert that doesn’t fit or a box lid that won’t close properly, forcing the entire batch to be reworked. This article explains the essentials of dimensions so you can provide accurate specifications before placing your order.
Box dimensions are calculated mathematically. Internal dimensions are derived by adding the insert thickness and a clearance allowance to the product dimensions; external dimensions are obtained by adding the cardboard thickness to the internal dimensions. The thicker the material, the greater the difference between internal and external dimensions—this is the key distinction between rigid gift boxes (made of thick greyboard) and folding cartons (made of thinner cardstock).
The more comprehensive the information provided to the manufacturer, the better. By supplying details such as product dimensions, quantity, insert requirements, and shipping methods, the manufacturer can calculate the recommended box style and insert design. Getting the dimensions right is the crucial first step that ensures everything else proceeds smoothly.
Common errors include: providing product dimensions without specifying the box style, confusing internal and external dimensions, overlooking the space occupied by the insert, and using inconsistent units of measurement. Any of these mistakes can lead to discrepancies in quotes and samples; the cost of reworking a batch is far higher than the effort required to ask a clarifying question.
When measuring the product, identify the maximum points. Measure the length, width, and height at their most prominent points, then factor in cushioning and clearance allowances. Inserts require extra space around the product—typically an additional 2–3 mm to 5–6 mm per side, depending on the product and the insert material’s thickness. Do not estimate dimensions for irregularly shaped products; take actual measurements, paying particular attention to the accuracy of curved sections.
