Is there a minimum order for custom shipping boxes?
No. We make custom shipping boxes with no minimum order, so you can order one box to test the fit and your shipping method before buying more.
What affects the cost of a custom shipping box most?
Box dimensions and corrugated grade matter most, because they set how much board is used. Print coverage and quantity come next, with finishes and inserts last.
Does a bigger box cost more to ship?
Often yes. Carriers bill on the greater of actual weight or dimensional weight, so a light product in an oversized box can be billed as if it were heavy. Check your carrier rules.
Should I choose single-wall or double-wall corrugated?
Choose single-wall for most parcels. Use double-wall for heavy, fragile or stacked loads or long transit. Ask us for a sample of each grade if you are unsure.
How do I get a quote for custom shipping boxes?
Send product size, weight and quantity through our quote page. We return a dieline and a written quote, and we beat any written quote you bring for the same specs.
Custom shipping boxes cost more or less depending on the box dimensions, the corrugated grade, how much printing goes on it, and how many you order. Size is the one buyers underestimate, because an oversized box costs more to make and more to ship. This guide covers each driver and how to compare two quotes properly.
Reviewed by the TBPB packaging team, October 2026.
Quick facts
| Topic | What to know |
|---|---|
| Minimum order | None. One box or thousands. |
| Main cost drivers | Dimensions, corrugated grade, print coverage, quantity |
| Typical board | Single-wall corrugated for most parcels; double-wall for heavy or fragile loads |
| Cheapest print option | One color on a kraft exterior |
| Hidden cost to watch | Oversized boxes raise carrier charges |
What makes one shipping box cost more than another?
Material and size come first, print second. A shipping box is mostly a sheet of corrugated board cut and folded, so the amount of board and its strength do most of the work in the price. Printing, inserts and finishes sit on top of that.
- Dimensions. Length, width and height set how much board the box uses and how many fit on a press sheet.
- Corrugated grade. Single-wall suits most parcels. Double-wall costs more and is for heavy or fragile contents or long transit.
- Print. A one-color logo on kraft is the lightest option. Full-color printing on both faces adds ink and prepress work.
- Style. A regular slotted box is the simplest. A die-cut mailer style needs a cutting die and more assembly care.
- Quantity. Setup is shared across the run, so each box gets cheaper as the count rises. We have no minimum, so you can start small.
How does box size change your real cost?
An extra inch in each direction makes the box cost more, and it can push you into a higher carrier charge as well. Carriers bill on whichever is greater, the actual weight or a weight calculated from the package volume (dimensional weight). A light product in a big box can be billed as if it were heavy. Check your carrier’s current rules before you finalize dimensions.
Worked example. Say the product is a boxed candle measuring 4 x 4 x 5 inches. Add about half an inch of cushion on every side, so the inside is 5 x 5 x 6 inches. If you instead use a standard 8 x 8 x 8 inch box because it is easy, you carry about 512 cubic inches of box around an 80 cubic inch product. The tighter box has 150 cubic inches of interior, less than a third of that volume, and it ships far more efficiently. Right-sizing is often the first saving to look at.
Single-wall or double-wall: which should you buy?
Single-wall, unless you can name a reason not to. Most parcels under normal weights ship fine in single-wall corrugated. Move to double-wall when the box holds heavy items, will be stacked on a pallet, or travels a long way with several handoffs. Paying for double-wall on a light T-shirt is waste. Under-specifying a case of glass is a worse mistake. If you are unsure, ask us for a sample in each grade.
How can you lower the cost without weakening the box?
Print less, size tighter, and choose the grade your product truly needs. Print only the outside in one or two colors, and leave the inside plain. Use a standard style before paying for a custom die. Order a trial quantity first, since we make custom shipping boxes with no minimum order, and move up in volume once the box works. You can read more about the whole category in our complete guide to custom shipping boxes.
How do you compare two shipping box quotes?
Match the spec on every line, then compare totals. A lower quote is often a thinner grade or a smaller box.
| Line to check | Why it matters |
|---|---|
| Inside dimensions | Some suppliers quote outside size, which is smaller inside |
| Corrugated grade and flute | Sets strength and stacking |
| Print colors and coverage | Often the biggest swing after size |
| Quantity | Unit cost changes with volume |
| Setup, die or plate charges | Can be buried or billed separately |
| Freight | Included, or added at checkout |
When is a shipping box the wrong product?
If your product is soft and light, such as apparel, a poly mailer or padded mailer weighs less and costs less to ship. If the unboxing is part of the sale, a mailer box gives a better first impression. For tall thin items, mailing tubes are a better fit. Browse corrugated boxes if you want the plain workhorse.
Questions buyers ask
Is there a minimum order for custom shipping boxes?
No. We make custom shipping boxes with no minimum order, so you can order one box to test the fit and your shipping method before buying more.
What affects the cost of a custom shipping box most?
Box dimensions and corrugated grade matter most, because they set how much board is used. Print coverage and quantity come next, with finishes and inserts last.
Does a bigger box cost more to ship?
Often yes. Carriers bill on the greater of actual weight or dimensional weight, so a light product in an oversized box can be billed as if it were heavy. Check your carrier rules.
Should I choose single-wall or double-wall corrugated?
Choose single-wall for most parcels. Use double-wall for heavy, fragile or stacked loads or long transit. Ask us for a sample of each grade if you are unsure.
How do I get a quote for custom shipping boxes?
Send product size, weight and quantity through our quote page. We return a dieline and a written quote, and we beat any written quote you bring for the same specs.
How to order
Tell us the product size, weight, and how you ship it, then give us a quantity. One box is fine. We send a dieline and a written quote. Got a written quote from someone else for the same specs? Bring it and we beat it, that is our price-beat guarantee. Design help, samples and shipping are free. Start with request a quote, or see our custom shipping boxes with no minimum order, and use the packaging cost estimator to test options.
