First aid packaging is one of the few cases where you genuinely should not start with the box. Start with the contents list, because a first aid kit is judged on whether the user can find the right item in seconds, and that is a layout problem before it is a dimension problem.
Lay the kit out before you measure anything
Put every item on a table in the arrangement you want a user to see the instant the lid opens. Group by urgency, not by size: bleeding control first, then burns, then minor wound care. Now measure the rectangle that layout occupies. That rectangle, plus clearance, is your internal length and width.
Then find the tallest item in the kit. It is usually a roller bandage, a saline or eyewash bottle, or an instant cold pack. That item sets internal depth for the whole box, and it is worth asking whether it could live in a separate pouch so the main tray can be shallower.
Contents standards affect the layout
Workplace first aid kits in the US are frequently specified against a published contents standard that defines Class A and Class B contents lists and several container types intended for different environments. That standard tells you what has to be in the kit and therefore how many compartments you need. It does not tell you how big the box is, and no supplier can certify your finished kit against it. Confirm which standard and which class applies to you, then design the tray to hold that list comfortably.
Container type changes the packaging job
| Container | What the paper packaging does |
|---|---|
| Rigid wall-mounted cabinet | Printed carton is the shipper and the retail pack, the cabinet holds the layout |
| Soft pouch or bag kit | Carton is a retail outer, sized to the flat-packed pouch |
| All-paper kit box | Carton is the kit itself, so the partition and the print inside both matter |
Print, legibility and the inside of the lid
The inside of the lid is prime real estate on a first aid box and it is routinely left blank. A printed contents list, a refill reminder and a simple index keyed to the tray compartments all cost nothing extra once you are already printing. Keep type large. A first aid box is read under stress by someone who may not be wearing their glasses.
Be careful with claims on the outside panel. Describe what is in the kit and leave regulatory or medical claims to your own compliance review. Packaging copy is not the place to assert a standard you have not verified for your specific contents.
Ordering
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, which means a box drawn to your exact contents layout tools no differently from a near-standard size. Turnaround is quoted per product across three lanes: rush, which combines expedited production with air freight, standard by air, and cost saver by sea. The floor is from about 7 business days, plus 2 to 5 for delivery, and specialty imported items can run up to about 12 weeks. Production runs out of West Chicago in the US and Guangzhou in China.
For the printed carton itself, medicine boxes covers the folding carton format, and corrugated boxes covers the sturdier kit and case format. Send your contents list, the tallest item height and a photo of your intended layout to request a quote.
