The number on the spec sheet is the diagonal of the screen. It tells you almost nothing about the box. Bezel width, hinge design and chassis taper vary between models, so the only reliable input is the closed machine on a flat surface with a tape measure across it. Measure it yourself, write the result down as length x width x depth, and treat that as the starting internal dimension.
The three measurements, plus the ones people forget
- Length and width of the closed chassis, taken at the widest points, including rubber feet, rear hinge bulges and any port covers that stand proud.
- Thickness with the lid closed, measured at the thickest end. Most laptops taper, and the thick end is the one that sets the box.
- Accessory stack. A power brick is usually the tallest single item in the box and frequently sets depth on its own. Measure it separately and decide whether it sits beside the machine or under it.
- Cushioning. Whatever holds the machine off the wall adds caliper on both sides. A moulded pulp tray, a corrugated fitment or a foam end cap each add a different amount, so pick the retention method before you fix the internal size.
Retail carton or shipper
| Question | Retail carton | Outer shipper |
|---|---|---|
| Job | Fit, presentation, unboxing sequence | Drop and compression protection in transit |
| Usual board | E flute litho laminated, or heavy folding carton | C flute or double wall corrugated |
| Full colour outside, often printed inside the lid | Plain kraft or one colour, shipping marks only | |
| Internal fit | Tight, with a fitment holding the machine | Clearance for cushioning around the retail carton |
If your laptops ship direct to consumers, plan both layers from the start. A retail carton designed as though it were also the shipper tends to arrive scuffed, and a shipper sized without allowing for the retail carton's own board thickness will not close.
Board, retention and print
E flute at about 1/16 inch caliper is the usual choice for a printed retail carton because it holds fine graphics without the wash boarding you get on heavier flutes. The outer shipper is normally C flute at about 3/16 inch, or double wall if the filled weight and the transit distance justify it. Retention matters more than raw board weight for a laptop: a machine that cannot move inside its fitment survives handling that a loose machine in a thick box will not.
Ordering and lead time
The minimum is 100 boxes. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Turnaround is quoted per product across three lanes: rush, which is expedited production plus air freight at a premium of roughly 7 to 25 percent depending on the job, standard on air, and cost saver on sea. The floor is about 7 business days in production plus 2 to 5 days for delivery, and specialty imported constructions can run longer, up to about 12 weeks. Production is split between West Chicago in the United States and Guangzhou in China.
Because the cutting die and the plates are included, a box cut to your exact chassis costs no more to tool than one built around a common size, which removes the usual reason to compromise on fit. To order, see custom laptop boxes. If the machine ships with batteries or is going overseas, read how to package electronics for shipping first, then send your measurements with a quote request.
