Why size matters
The right mailer box size does two jobs at once. It protects the product so nothing shifts or breaks, and it controls your shipping cost by not paying to move empty space. A box that is too big wastes money on every shipment and lets the product rattle. A box that is too tight is hard to pack and can damage the product. Getting the size right is one of the easiest ways to save money and improve the customer experience.
How to measure
Mailer boxes are described by their internal dimensions, in the order length by width by height (or depth). Measure your product at its longest, widest, and tallest points. If you use void fill, inserts, or wrap the product, add room for that. A small allowance on each dimension usually gives a snug, protective fit. If you are shipping several items together, measure them as they will be packed.
Allowing for protection and inserts
If your product is fragile or premium, plan for protection inside the box. A custom insert in foam, molded pulp, or paperboard holds the product in place and elevates the unboxing. Inserts add to the internal size you need, so decide on protection before you finalize the box dimensions. Our design team can recommend the right insert and adjust the box size to fit.
Controlling shipping cost
Carriers often charge by dimensional weight, which means the size of the box can matter as much as the weight of the product. A box cut to your product keeps dimensional weight low and your shipping bill down. This is a big reason custom sizing beats forcing your product into a stock box.
Custom sizes with no minimum
Because we make mailer boxes custom to your product with no minimum order, you are not stuck choosing from a few stock sizes. Tell us your product or its dimensions and we will recommend the right internal size and any insert, then send free samples so you can check the fit before a full order.
Frequently asked questions
What dimensions do I give you? Give us the product size or the box internal size you need, length by width by height. If you are not sure, tell us the product and we will size it for you.
Should I add extra space? A small allowance for protection or inserts is wise. We will help you get a snug, protective fit without oversizing.
Can I get a sample to check the fit? Yes. We provide free samples so you can confirm the size and fit before ordering.
