Tube sizing goes wrong in one specific way: people measure the wrong side of what they are shipping. The tube's length has to clear the dimension that runs along the roll, and its diameter has to clear the thickness the roll ends up at. Get those two right and everything else is a wall thickness and an end cap decision.
The three measurements
| Measurement | What it controls | How to determine it |
|---|---|---|
| Inside diameter | Whether the rolled contents fit | Roll the item as tightly as you are willing to and measure the roll's diameter, then allow clearance |
| Length | Whether the contents fit end to end | Measure the dimension that runs parallel to the tube, then add clearance for end caps |
| Wall thickness | Crush resistance in transit | Heavier walls for long tubes, valuable contents or rough handling |
Picking a diameter
A single thin print rolls down to almost nothing, so a narrow tube is fine and costs less to ship. Heavier stock resists rolling tightly, and several prints together, or a canvas, produce a much thicker roll. Two practical rules: never size the tube so tightly that the roll has to be forced in, because it will be damaged coming out, and remember that a tighter roll means a stronger curl in the print when it is unrolled at the other end. If the flatness of the delivered item matters, go up a diameter rather than down.
Picking a length
Measure the dimension that will run along the tube. For a poster rolled from the short edge, that is the poster's width. Add a small allowance so the contents do not sit hard against the end caps. Do not add too much: a long empty section lets the contents slide and take the impact of a drop directly.
Before you fix a length, check your carrier
Carriers apply maximum length limits and combined length-plus-girth limits, and long tubes are one of the easiest ways to cross a surcharge threshold without realising. Confirm the limits with the carrier you actually use before locking a tube length, especially if you are considering anything over about a yard.
End caps and closure
Plastic or paper end caps are the usual closure and they need to be a friction fit rather than loose. Tape over the cap for anything valuable, since a cap that pops in a sorting facility means the contents leave the tube. If the tube is being used for retail presentation rather than mailing, a printed cap or a sealed label reads better than tape.
Printing a tube
A printed tube is either printed on a wrap applied to the body or supplied with a printed label. Because the surface is curved and continuous, artwork has to be designed for a wrap rather than a flat panel, and the seam is a real design consideration rather than an afterthought. Design support is included and will lay your artwork out on the wrap.
Minimums and lead time
The minimum is 100 units per size and artwork. Bulk pricing starts from about $0.48 per unit, confirmed on the written quote, and US shipping is included. Turnaround is quoted per product across three lanes: rush (expedited production plus air freight, roughly 7 to 25 percent more), standard (air) and cost saver (sea). Production starts from about 7 business days plus 2 to 5 days for delivery, and specialty imported items can run up to about 12 weeks.
Send the flat dimensions of what you are shipping and the stock weight to the quote form. Related: poster tube dimensions and how to choose box size.
