Hand tools break packaging in a predictable way. They are small, they are heavier than the box looks like it should carry, and they have protrusions. A tape measure adds a belt clip and a thumb lock to that list, and both stand proud of the case.
Measure with the clip on
Take the tape with the clip fitted, since that is how it sells, and measure the overall depth front to back including the clip at its furthest point. Then measure width and height across the housing, checking the blade slot lip and the lock button. If the tape has a rubber over-mould, measure the mould, not the shell beneath it.
Write the result as internal length x width x depth and confirm on the quote that the numbers are internal. On a small dense pack the board adds real external size, and a case pack planned on internal numbers will not fit.
Weight is the actual design problem
A long steel tape is heavy in the hand, and that weight sits in a small footprint. In a light folding carton the load concentrates at the tuck flap and the pack tears open in transit or on the peg. Two practical answers: move up in board so the panel carries the load, or switch to a litho-laminated E-flute construction, which mounts a printed sheet to fluted board and gives you photographic print with real crush and tear resistance. If it hangs, the hang feature has to be reinforced or die cut through a doubled panel.
Comparing the three formats
| Format | Dimensions that drive it | Best suited to |
|---|---|---|
| Printed hang card, tool banded or tied | Card footprint and hang tab height; the tool sets the card size | Low cost, high visibility, tool is touchable on shelf |
| Blister or clamshell on a card | Cavity depth over the clip, plus the sealed flange width around it | Theft resistance and a sealed pack; the flange adds to every edge |
| Folding carton with a retainer | Internal cavity plus retainer thickness; the closure carries the weight | Gift and trade pack presentation, full print surface, no plastic |
Peg, shelf and multi-pack
Hardware is heavily peg-merchandised, so get the retailer's peg spacing and hang tab rules before the height is fixed. If you are selling a two or three piece set, decide whether the pack presents them side by side, which widens the facing, or stacked, which deepens it. Shelf width is usually the scarcer resource.
Minimum, price and lead time
Minimum order is 100 units. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Die and plates, design support, US shipping and a digital proof before anything prints are included. Lanes are Rush (expedited production plus air freight), Standard (air) and Cost saver (sea), with a floor of from about 7 business days, plus 2 to 5 for delivery. Specialty imported items can run up to about 12 weeks, and Rush carries about 7 to 25%, depending on the job.
Send the tape with the clip measured, the packed weight and whether it hangs or sits, and we will quote a construction that survives the peg at /quote/. For the card and blister routes, see blister cards and header cards.
