Sizing a telescoping box is different from sizing a one piece carton, because you are designing two boxes that have to fit each other as well as the product. Get the base right and the lid wrong and you end up with a lid that binds, or one that slides off in transit. The sequence below keeps both under control.
Step 1: size the base to the contents
Measure the product at its widest point on each axis, in the state it ships, including any insert, tissue or void fill. Add clearance so the product loads without a fight, typically a couple of millimetres per side for a rigid item and more if a soft insert has to compress. That total is the base's internal dimension. Write it down as internal length x width x depth.
Step 2: size the lid to the base
This is the step that goes wrong. The lid does not fit the product, it fits the outside of the base. So:
- Take the base internal dimension.
- Add the board thickness twice, once for each wall. On rigid construction, chipboard is typically specified in millimetres and commonly runs in the 1.5 to 3 mm range, so two walls is a visible amount. On corrugated, the flute caliper does the same job: E flute is about 1/16 inch, B about 1/8 inch, C about 3/16 inch.
- Add a working clearance so the lid slides rather than wedges. Too little and the lid sticks or tears the wrap. Too much and it rattles or lifts off.
- The result is the lid's internal dimension.
When you send this on a quote request, label every number as internal or external. Most problems on a first telescoping order come from one side quoting one and the other reading the other.
Step 3: choose the overlap
| Style | Lid depth | Why you would choose it |
|---|---|---|
| Full telescope | Covers the full depth of the base | Maximum strength and a clean, seamless exterior. The lid becomes a second wall on every side |
| Partial telescope | Covers part of the base depth | Shows a band of the base as a design feature and uses less board than a full cover |
| Shallow slip lid | Covers a small top band | Gift presentation where the base is the decorated element |
Full telescope adds genuine stacking strength because the double wall runs the whole height. If the box will be stacked or shipped without an outer carton, that is the version to ask for.
Step 4: decide depth against the contents, not against the look
A telescoping box tolerates a deep base better than a tuck end carton does, because the lid holds the walls square. But a base much deeper than its footprint will bow under a hand. If your product is tall and narrow, say so on the quote and we will look at board grade rather than just cutting a taller base.
Ordering and turnaround
Minimum order is 100 boxes, counted as complete sets of lid and base. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote, since a two piece box uses more board and more finishing than a single carton. Die and plates for both pieces, design support, US shipping and a digital proof before anything prints are included.
Turnaround is quoted per product in three lanes: rush (expedited production plus 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, and specialty imported items can run up to about 12 weeks. We produce in West Chicago, US, and Guangzhou, China.
Send the product measurements and tell us whether you want a full or a partial telescope, and we will work out the lid clearance and confirm both pieces on a written quote at /quote/. If you are still deciding between formats, what size telescoping box do I need works through it by scenario, and two piece boxes is where to order.
