Phone case boxes fail in one of two ways: the case rattles because the box was sized to the phone, or the box will not close because nobody measured the camera bump. Both are measuring problems, not manufacturing problems. Here is the sequence that avoids them.
Measure the case at its worst point
Take the case on its own, off the phone, and measure three things.
- Length and width: the outer edge of the case, not the phone's screen size. A rugged case can be several millimetres larger on each side than a slim one for the same handset.
- Thickness: at the camera cutout ring, which is almost always the high point. A case measured on its flat back will not fit the box you specify.
- Curvature: if the case has a pronounced lip or a kickstand, measure with that feature in its shipping position.
Add clearance after that. Roughly 1 to 2 mm on length and width is enough for a bare case that sits loose. If the case sits in a paperboard tray or a folded insert, add the insert's own material thickness on each side it touches. Write the final number as internal length x width x depth and say the word internal on your quote request.
What changes the carton beyond size
On a box this small, the spec decisions that matter are not dimensional.
| Decision | What it affects |
|---|---|
| Board caliper, measured in points where one point is a thousandth of an inch | Whether the panel stays flat behind a shelf hook or bows. Thin board on a small carton reads cheap in the hand |
| Window film | Lets the case colour sell itself, but cuts printable area and adds a step to production |
| Hang tab or euro slot | Adds height above the face panel, typically around an inch, and needs enough board strength at the tab to survive repeated handling |
| Insert or tray | Stops rattle and lifts the case to the opening. Eats internal depth, so decide on it before you fix the dimensions |
| Finish, such as soft touch lamination or spot gloss | Pure presentation. Has no effect on fit, but does affect price per unit |
Multi-SKU ranges: one box or many
If you carry cases for several handsets, you have a genuine choice. One shared carton sized to your largest case keeps the count per SKU high and the tooling simple, at the cost of some rattle on the smaller models, usually solved with an insert. Separate cartons per handset fit better and look tighter on shelf, but split your quantity across more dies. Since the die is included on every custom order, the argument for sharing a carton is about inventory and forecasting, not about tooling cost.
Ordering and lead time
The minimum is 100 boxes per configuration. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Die, plates, design support, US shipping and a digital proof are included, so you see exactly what prints before it prints.
Turnaround is stated per product in three lanes: rush, which combines expedited production with air freight at a premium of about 7 to 25% depending on the job, standard by air, and cost saver by sea. The floor is from about 7 business days, plus 2 to 5 days for delivery. Specialty imported items can run up to about 12 weeks. Our plants are in West Chicago, US, and Guangzhou, China.
Send the three case measurements and tell us whether the box hangs or sits, and we will confirm caliper, insert and lane on a written quote at /quote/. For the broader accessory range and its retail formats, see cell phone accessories packaging.
