Start with the product
Product-to-box size calculator
Turn a measured product into a practical starting carton size. The calculator adds handling clearance and cushioning on every side, then estimates the outside size from the board thickness.
Change any value and calculate again for a new result.
01 / Method
How to use this tool
- 1
Measure the product at its widest points.
- 2
Enter clearance and cushioning per side, not as a total.
- 3
Choose a board thickness and compare the result with available carton sizes.
02 / Model
Assumptions
- The product is treated as a rectangular envelope.
- Clearance and cushioning are applied equally to both sides of each axis.
- External dimensions add two board thicknesses to each internal axis.
03 / Boundaries
Limitations
- Does not model flaps, bulges, irregular shapes, compression, or manufacturing tolerances.
- The smallest calculated size may not be manufacturable or safe in transit.
04 / Common questions
Frequently asked questions
Is clearance entered per side?
Yes. A 5 mm entry adds 10 mm to each product dimension.
Are the external dimensions exact?
No. They are a planning estimate. Carton style, score allowances, board caliper, and converting rules affect finished dimensions.
Should I use product dimensions from a drawing?
Use verified maximum physical dimensions when possible, including protrusions and expected production variation.