A doll box is a display box first and a shipping box second, and that ordering drives every dimension on it. The doll is held in a fixed pose, visible through a window, anchored so it does not move in transit, and surrounded by enough frame for the branding. The doll itself is only one of four things setting the size.
Measure the presentation, not the product
Pose the doll exactly as it will be displayed, on its stand or backer card, with all accessories in place, and then take the measurements.
- Height. From the bottom of the base or the lowest anchored point to the top of the hair or headdress. Hair is the single most commonly underestimated dimension on this format.
- Width. Across the widest point of the posed figure, which is usually an outstretched arm, a skirt, or the display base.
- Depth. Across the deepest item in the pack. If a boxed accessory or a brush sits behind the doll, that item sets the depth, not the doll.
Add about 1/4 in of clearance all round so the film does not press against the figure, then write the result as internal length x width x depth and mark it internal.
Anchoring, and why it changes the box
Dolls are held with T bar anchors, plastic ties through a backer card, elastic loops or a moulded tray. Each of these adds material behind the doll, which adds depth.
| Anchor method | Adds to depth | Notes |
|---|---|---|
| Backer card with tie tabs | Card caliper plus the knot allowance | Cheapest, needs a stiff card so it does not bow |
| Moulded tray or blister | The full tray depth | Best retention, highest tooling and material cost |
| Die cut corrugated fitment | Board caliper plus the cavity | Paper only pack, easier to recycle |
| Elastic loops through the back panel | Very little | Fast to assemble, less secure for a heavy figure |
If the pack is paper only for recycling reasons, the fitment route is the one to specify. The options are set out on the insert packaging page.
The window
A window is an aperture cut into a printed panel with a clear film laminated behind it. Two rules govern its size. The film has to be glued to a flat area, so it cannot run to a score line, and the aperture needs a printed frame around it for structural reasons as much as for branding. Half an inch of frame is a reasonable planning minimum, and a corner radius on the aperture stops the panel tearing. A very large window in a light board panel will flex, so either step the board up or break the aperture with a bar. Format options are on the window boxes page.
Shipping the display box
Retail doll boxes are usually shipped inside a master case rather than alone, because the window panel will not survive a courier on its own. Size the master to hold a whole number of display boxes, then check the master footprint against a 48 x 40 in pallet so nothing overhangs. If the doll box also ships direct to consumer, it needs an outer mailer, and that is a separate item on the quote.
Minimum, price and turnaround
Doll and toy packaging starts at 100 units, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The cutting die, the printing plates, design support, US shipping and a digital proof are included, so an aperture and cavity cut to your exact figure costs no more to tool than a near standard size. Turnaround is stated per product in three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days of production plus 2 to 5 days for delivery. Windowed and specialty imported constructions can run up to about 12 weeks, so give a seasonal launch plenty of room.
Send the posed height including hair, the widest point and the accessory depth, and we will draw the window and the fitment around it. Start at request a quote, or order from the custom doll boxes page.
