Size calculator · runs in your browser
Tuck box size calculator
To size a tuck box, add clearance to your product's length, width and depth (about 1/16 in each for a rigid product) to get the inside size; the outside is about two board thicknesses larger. This calculator does that, suggests a tuck style and board in points, and finds the closest size with a listed price.
Rules of thumb, not a guarantee of fit: fold a paper mock-up from the dieline, and check the size on your digital proof before anything prints.
How do you size a tuck box for a product?
- Measure the product. Measure the product (or its inner wrap) at its widest points: length across the front, width front to back, depth standing up.
- Set the clearance. Keep the default 1/16 in clearance for a snug fit, or add more for soft or uneven products.
- Choose the board. Pick the board thickness; the outside size grows by about two board thicknesses on each dimension.
- Say how it is sold. Shelf, peg hook or shipped on its own, plus the weight: these choose the suggested style and board.
- Use the result. Open the size in the dieline generator, see the closest size with a listed price, or send it in the quote form.
Measuring a bottle with a dropper or pump? Measure to the tallest point. See how to measure a tuck box step by step, and the tuck box sizes chart for standard sizes per style.
Sizing questions
How much clearance should a tuck box have?
About 1/16 in on length and width is a common rule of thumb for a rigid product such as a jar or bottle, so it slides in without rattling. Soft, uneven or wrapped products need more, often 1/8 in. Depth usually gets 1/16 in too, so the tuck flap closes flat.
What is the difference between inside and outside dimensions?
Inside dimensions are the space for the product; tuck boxes are quoted and made by inside size, L x W x D. The outside is bigger by about two board thicknesses on each dimension: around 0.04 in for 18pt board and about 1/8 in for E-flute corrugated.
Which board thickness should I choose?
As a rule of thumb, 16-18pt paperboard suits small, light products, 18pt most products under about a pound, and 20-24pt taller or heavier cartons. Products that ship on their own or weigh a few pounds move to E-flute corrugated. One point is 0.001 in.
Which tuck style does the calculator suggest?
Reverse tuck end for most shelf products, an auto bottom above about a pound, a hang tab for peg hooks and the tuck front mailer in E-flute when the box ships on its own. These are rules of thumb, the same ones the style picker on the home page uses.
How do I write a tuck box size?
Length x width x depth, inside, in inches: for example 2 x 2 x 6 in. Length and width are the opening (front panel and side panel); depth is the height of the carton standing up. Put the three numbers in the quote form.