Guide · updated 2 Nov 2026
How to measure a tuck box
Measure a tuck box on the inside, written length x width x depth: length is the front panel, width the side panel and depth the height standing up. To size a new box, measure your product at its widest points and add clearance, about 1/16 in on each dimension for a rigid product.
Which dimension is length, width and depth?
Tuck box sizes are written length x width x depth (L x W x D), inside, in inches. Length and width are the opening: length is the wider panel (the front), width the narrower one (the side). Depth is the height of the carton standing up. A tall carton for a bottle 2 in across and 6 in high is 2 x 2 x 6 in.
How do you measure a product for a tuck box?
- Measure L. Measure the widest point of the product (or its inner wrap) across the front: that is L.
- Measure W. Measure front to back: that is W.
- Measure D. Measure the height standing up: that is D. For a bottle with a dropper or pump, measure the tallest point.
- Add clearance. Add a little clearance so the product slides in: about 1/16 in on L and W is a common rule of thumb; more for products with soft or uneven edges.
- Write it down. Write the result as L x W x D, for example 2 x 2 x 6 in, and put it in the quote form.
Measuring a bottle with a dropper, pump or cap? Measure to the tallest point. An insert takes space too: send the product size and we size the carton and insert together.
Inside or outside dimensions: which do you give?
Inside. Cartons are made and quoted by the space inside, so the product fits whatever board is used. The outside is bigger by about two board thicknesses on each dimension:
| Board | Thickness | Outside is larger by about |
|---|---|---|
| 16pt paperboard | 0.016 in | 0.03 in |
| 18pt paperboard | 0.018 in | 0.04 in |
| 24pt paperboard | 0.024 in | 0.05 in |
| E-flute corrugated | about 1/16 in | about 1/8 in |
Board thicknesses as listed on the materials pages; E-flute is an industry figure. Two thicknesses per dimension is a rule of thumb.
What are the common measuring mistakes?
- Giving outside sizes of an old box as the new inside size: the new carton comes out a little large.
- Swapping width and depth: depth is always the height standing up.
- Forgetting caps, pumps and droppers when measuring height.
- No clearance: a carton cut to the exact product size is hard to fill and can bulge.
Let the size calculator do the maths, check standard sizes in the tuck box sizes chart, then fold a paper test from the dieline generator.
Questions
Do you give inside or outside dimensions for a tuck box?
Inside. Tuck boxes are made and quoted by the space inside, written length x width x depth in inches. The outside is larger by about two board thicknesses on each dimension, so the size calculator shows both.
Which number comes first, width or depth?
Length, then width, then depth. Length is the wider face (the front panel), width is front to back (the side panel) and depth is the height of the carton standing up. A tall carton for a 2 x 2 x 6 in bottle is written 2 x 2 x 6.
How much bigger than the product should the box be?
About 1/16 in on length and width is a common rule of thumb for a rigid product such as a jar or bottle, plus about 1/16 in on depth so the lid closes flat. Soft, uneven or wrapped products often need 1/8 in.
How do I measure an existing box I like?
Open it and measure inside, wall to wall, for each dimension. If you can only measure the outside, subtract about two board thicknesses: around 0.04 in for paperboard cartons and about 1/8 in for E-flute mailers.