Stationery packaging is mostly a geometry problem. The contents are standard sizes, they are flat, and they are usually sold as a set, so the difficulty is fitting several rigid rectangles into one box without wasted space or rattle. Start from the paper.
Paper formats to size against
| Format | Size | Common product |
|---|---|---|
| US Letter | 8.5 x 11 in | Pads, printed sheets, portfolio inserts |
| Half letter | 5.5 x 8.5 in | Notebooks, planners |
| A4 | 210 x 297 mm | Pads, folders |
| A5 | 148 x 210 mm | Notebooks, journals |
| A6 | 105 x 148 mm | Pocket notebooks, note cards |
Then add for what the format does not tell you: a hard cover overhangs the text block, a spiral or wire binding adds thickness on one edge and often sticks out beyond the cover, and an elastic closure adds a millimetre or two across the whole book. Measure the finished product, not the paper spec.
Boxing a set rather than an item
Most stationery is sold as a kit: a notebook, a pen, a set of cards, maybe a sticker sheet. The box is easy, the interior is the work. A divided chipboard or corrugated platform holds each piece in its own well, keeps the pen from rolling across the notebook cover and makes the box photograph well when it is opened. That platform is a second dieline designed alongside the box, and the tolerances have to account for the fact that a pen is round and a notebook is not. Our guide to custom insert packaging covers the material choices.
Build options
- Two piece rigid. The default for gift sets and premium notebooks, arrives assembled.
- Sleeve over a tray. Lets the product edge show, good for retail shelves.
- Folding carton. Cost efficient, ships flat, right for single items such as a boxed pen.
- Mailer. For subscription stationery going direct to a customer.
Print and surface
Stationery buyers are paper people, so the board is part of the product. Uncoated stocks, textured wraps and blind embossing all work well here and all mute colour, so approve the digital proof rather than the screen file. Foil is common on stationery gift boxes, and it needs its own tooling on the first run. If you want the full finish comparison, it is on luxury custom packaging.
Ordering
Minimum 100 boxes per design. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before anything prints are included, which means a box built to your exact notebook trim costs no more in tooling than a generic size.
Turnaround is stated per product across three lanes: rush is expedited production plus air freight, standard is air, and cost saver is sea. The floor is from about 7 business days plus 2 to 5 for delivery, and specialty imported items, including some rigid and heavily finished builds, can run up to about 12 weeks. Rush carries a premium of about 7 to 25% depending on the job. Production runs at West Chicago in the US and Guangzhou in China.
If your set is built around cards or envelopes, the sizing reference on card box dimensions is the place to start. Otherwise send the finished dimensions of every item in the set through the quote form.
