Pajamas have no fixed packed size. A two piece set folded in thirds and banded is a completely different box from the same set folded in half and laid flat. So the first decision is not the box, it is the fold. Once the fold is fixed, the dimensions follow in about five minutes.
Fix the fold, then measure the stack
- Fold a real set the way your packing team will fold it every time. Write that fold down as a packing instruction, because it is now part of your spec.
- Press the stack the way it will be pressed in the box, including any tissue, belly band or card.
- Measure the stack: length, width, and height at its tallest point, which is usually a seam or a waistband.
- Add clearance. About 1/4 inch on length and width gives the packer room to work without the garment bunching at the corners. Add a little on the height if the set is fluffy fleece rather than flat cotton.
- Record it as internal length x width x depth, and confirm on the quote that the numbers are internal.
Handling a size run without multiplying dies
Most sleepwear ranges span several sizes and two or three fabric weights. Fold one of each extreme, measure them, and you will usually find the footprint barely moves while the stack height does. That gives you three workable options.
| Approach | Works when | Trade off |
|---|---|---|
| One box sized to the largest stack | Height difference across the range is small | Small sizes sit loose. A tissue wrap or a band fixes the look |
| One footprint, two depths | Fleece and cotton sit far apart on height | Two dies, but both are included on custom orders, so the cost is in inventory not tooling |
| Mailer style that folds to the contents | Direct to consumer shipping rather than retail shelf | Less shelf presence, better freight density |
Board, print and what the box has to survive
A pajama box carries a light, soft load, so structural strength is rarely the constraint. What matters is whether it is a retail box that sits on a shelf or a shipper that travels alone. A folding carton in a decent caliper, measured in points where one point is a thousandth of an inch, is the normal retail answer, often with a window so the fabric shows. If the box ships direct to a customer with no outer carton, move to E flute corrugated, about 1/16 inch thick, which keeps the printed surface but adds a crush layer. Kraft board reads natural and hides scuffs from transit. Bleached white board gives cleaner colour if the print is photographic.
Ordering and turnaround
The minimum is 100 boxes. Pricing runs from about $0.48 per unit at bulk volumes and is confirmed on your written quote, because window film, board caliper and print coverage all move it. The die, the plates, design support, US shipping and a digital proof before anything prints are included.
Turnaround is quoted per product across three lanes. Rush combines expedited production with air freight and carries a premium of about 7 to 25% depending on the job. Standard ships by air. Cost saver ships by sea and suits seasonal sleepwear planned months ahead. The floor is from about 7 business days, plus 2 to 5 days for delivery, and specialty imported items can run up to about 12 weeks. Production is in West Chicago, US, and Guangzhou, China.
Fold a set, measure the stack, and send us those three numbers with a note on fabric weight. We will confirm the board and the lane on a written quote at /quote/. For the apparel formats themselves, see custom clothing boxes.
