A pendant box is the smallest thing in most packaging ranges, and small boxes are unforgiving. At this scale the wall thickness is a large fraction of the total size, and the insert takes up more of the cavity than the jewellery does. So the sizing order is inverted compared with a larger box: insert first, then cavity, then box.
Start with the insert
Almost every pendant box holds the piece on a pad, and the pad type decides the cavity.
- Slot pad. A foam pad with a slit that grips the chain. It needs enough material either side of the slot to stay stiff, which sets a practical minimum pad width well above the pendant width.
- Flat pad with a hidden chain well. The pendant shows, the chain is tucked under or behind. Adds depth rather than width.
- Hinged clip. Holds a ring or a bail upright. Adds height, and the lid has to clear the clip when closed.
- Printed card with a die cut slit. Cheapest, flattest, and the one that works for ecommerce where the box must stay thin.
Measure the pad you have chosen, then place the pendant on it and measure the assembly. That assembly, plus roughly 1/16 to 1/8 in of clearance, is your internal cavity.
Measure the pendant properly
Three things get missed. The bail, which is the loop the chain passes through, adds height above the stone. The jump ring adds a little more. And the chain, if it ships with the pendant, has to go somewhere: coiled behind the pad, tucked into a well, or threaded through a slot. Decide where the chain goes before you fix the depth, or you will end up with a box that closes on the chain and creases the pad.
Rigid or folding, and what it does to the outside
| Construction | Typical wall behaviour | Best for |
|---|---|---|
| Rigid two piece, wrapped chipboard | Chipboard commonly 1.2 to 3 mm, wrapped both sides, so the box grows noticeably outside the cavity | Counter sales, gifting, perceived value |
| Hinged rigid | Same wall build, plus a hinge spine that adds to one dimension | Presentation where the lid should stay attached |
| Folding carton with a tray | Board caliper only, so external is close to internal | Ecommerce, thin profile, lower shipping cost |
The chipboard range above is industry-typical and offered as a planning reference. The exact caliper used on your job is confirmed on your quote.
The ecommerce constraint
If the box ships alone rather than being handed over a counter, thickness is money. Flat mail rates are banded by depth, and a rigid box that is a few millimetres over a threshold can move the whole order into a higher band. Check the current bands with your carrier before you choose rigid over folding, because on a pendant it is often the deciding factor rather than the look.
What an order looks like
Pendant boxes start at 100 units, from about $0.48 per unit at bulk volumes, confirmed on your written quote, with the die, the plates, design support, US shipping and a digital proof included. Turnaround is stated per product in three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days of production plus 2 to 5 days for delivery. Rigid and specialty imported constructions can run up to about 12 weeks, which is worth knowing if you are planning for a gifting season.
Send the pendant measurements including the bail, tell us where the chain sits, and we will size the pad and the cavity together. Start at request a quote, order from the custom jewelry display boxes page, or if the piece includes a full chain, see necklace box dimensions.
