A keyboard is long, thin, heavier than it looks and unforgiving about corner drops. The good news for sizing is that the key field follows a published standard, so you can estimate the carton before a sample lands on your desk and confirm it afterwards.
Key pitch does most of the maths
Standard keyboard layouts space keys at 19.05 mm (0.75 in) between centres, and layouts are described in key units where 1u is one of those steps. Multiply units by 0.75 in and you have the key field. The table below is that multiplication, not a list of stock boxes.
| Form factor | Width in key units | Key field width (units x 0.75 in) |
|---|---|---|
| Full size, with numeric pad | 22.5u | About 16.9 in |
| Tenkeyless | 18u | About 13.5 in |
| 75% compact | 16u | About 12 in |
| 65% compact | 16u | About 12 in |
| 60% compact | 15u | About 11.25 in |
The case adds to every one of those numbers. Bezels range from almost nothing on a low profile board to more than half an inch on a gasket mounted case, and a wrist rest or a volume knob changes the footprint again. So use the key field to sanity check the quote and then measure the actual board at its widest, which is normally the case, not the keys.
What else has to fit
Very few keyboards ship alone. Before you fix the internal depth, list what rides in the same carton: a detachable cable and its coil, a keycap puller, spare switches, a manual, a warranty card, a dust cover. Each of those either sits in its own compartment or adds to the stack height over the board. A cable coiled under the keyboard is the single most common reason a first sample will not close.
- Measure the keyboard over the case with the feet folded flat, length and width.
- Measure the tallest point, usually the back edge or the top of the tallest keycap row.
- Lay out the accessories as they will ship and measure that block separately.
- Add 1/8 to 1/4 in of clearance per side for a retail carton, more if an insert wraps the board.
- Record everything as internal length x width x depth.
Protection, and why a long box needs help
A long, narrow box flexes in the middle, which is where an aluminium case gets marked and a hot swap socket gets stressed. Most keyboard packs use two layers: a printed retail carton sized close to the board, then a shipper with cushioning, or a single corrugated carton with a fitted tray. A paperboard tray that suspends the board off the floor of the box is usually enough for courier shipping and keeps the pack recyclable. Foam is the choice when the case is heavy and the finish is delicate.
Ordering
The minimum is 100 boxes, and pricing starts from about $0.48 per unit at bulk volumes, confirmed on a written quote. Because the die and plates are included, an internal size built around your exact case costs no more to tool than a near standard one. Turnaround is quoted per job in three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days, plus 2 to 5 for delivery, and specialty imported constructions can run up to about 12 weeks.
Send the case dimensions, the accessory list and the loaded weight to the quote form and we will come back with a carton and a tray option. Related: custom electronic boxes and insert packaging.
