Blanket packaging goes wrong in one predictable way: the box is specified against the blanket's finished size and then has to hold a compressed, relaxed, unevenly folded textile that behaves nothing like a flat sheet. Size from the pack, and the rest is straightforward.
Use mattress sizes as the reference, not blanket sizes
There is no binding standard for how large a blanket is cut. There is one for the bed it covers. US mattress dimensions are stable and published, and every blanket is cut to drape over one of them:
| Bed | Mattress size (industry standard) |
|---|---|
| Twin | 38 x 75 in |
| Twin XL | 38 x 80 in |
| Full | 54 x 75 in |
| Queen | 60 x 80 in |
| King | 76 x 80 in |
These are industry-typical reference figures for the bed, not iBox stock box sizes. Use them to sanity check which size tier you are packing, then measure your own pack for the actual box.
Measure the compressed pack
- Fold and compress a production blanket exactly as your fulfilment team will, including any vacuum or roll compression.
- Leave it for an hour. Textiles relax, and the relaxed depth is the number the box has to hold.
- Measure length, width and depth of the relaxed block at the thickest point, not the average.
- Add clearance for tissue, a ribbon, or a printed sleeve if those ship inside the box.
State the result as internal length x width x depth and mark it internal on the quote, because on a deep box the difference between inside and outside is large enough to matter.
Mailer or shipper
A blanket is light for its volume, which pushes it straight into dimensional weight territory. Two structures are normally in play. A die cut mailer with a tuck front closes flat, prints edge to edge and suits a single retail unit going direct to a customer. A regular shipper in double wall board suits multi-unit or wholesale movement and stacks better on a pallet. If you are going direct to consumer, the mailer almost always wins on both unboxing and freight, provided the compressed depth is genuinely stable.
Ordering and turnaround
Minimum order is 100 boxes, and pricing runs from about $0.48 per unit at bulk volumes, confirmed on your written quote. Die and plates, design support, US shipping and a digital proof before anything prints are included. Because the die is included, a box drawn around your compressed pack costs no more to tool than a near-standard size does. Three lanes are quoted per product: rush pairs expedited production with air freight, standard ships by air, cost saver ships by sea, from about 7 business days, plus 2 to 5 for delivery. Specialty imported items can run up to about 12 weeks. Boxes are made in West Chicago and in Guangzhou.
For the shipper version, see custom shipping boxes, and for the direct-to-customer version see mailer boxes. Send the measured compressed block, your fibre type and whether the pack is vacuum compressed to request a quote.
