A TV is the one product where the number on the box is not a dimension of anything you can measure with a rule. Screen sizes are diagonals. To size packaging you need the width and the height, and those come from the aspect ratio.
Panel dimensions derived from the diagonal
For a 16:9 panel, width is the diagonal multiplied by about 0.872 and height is the diagonal multiplied by about 0.490. This is geometry, not a product spec, so it holds for any 16:9 screen.
| Diagonal (in) | Screen width (in) | Screen height (in) |
|---|---|---|
| 32 | 27.9 | 15.7 |
| 43 | 37.5 | 21.1 |
| 50 | 43.6 | 24.5 |
| 55 | 47.9 | 27.0 |
| 65 | 56.7 | 31.9 |
| 75 | 65.4 | 36.8 |
| 85 | 74.1 | 41.7 |
These are screen areas only. Measure the actual chassis, because bezel width varies from almost nothing to a visible frame, and because the rear housing around the electronics is deeper than the panel edge.
What goes in the box besides the screen
Almost never just the screen. Plan the depth around the full contents:
- The panel itself, face protected, in an EPS or moulded pulp cradle top and bottom.
- The stand or legs, detached, which are heavy and hard-edged and should never sit loose against the panel.
- Remote, batteries, power cable, mounting hardware, documentation, usually in a shallow accessory tray.
- A slip sheet or cloth on the screen face, which adds a little to depth but prevents the scratch that makes a unit a return.
Construction and handling
Large flat packs travel on their edge, not on their face, so the bottom edge is where the drop energy lands and where the cradle has to be strongest. Double wall board is standard at these footprints, with the panel suspended so it never touches an outer wall. Hand holes matter: a 65 inch box is a two-person lift, and a box without a defined grip gets carried by its edges and crushed there. Print a clear this-way-up and a do-not-lay-flat instruction, because the most common damage cause is a box stacked on its face in a back room.
Check the shipping method before you tool
Girth is twice the width plus twice the height. US ground services commonly publish a maximum of 165 inches for length plus girth and a 108 inch maximum length, with oversize surcharges biting long before those ceilings. Run your candidate outer dimension through that arithmetic with your carrier's current rate card in front of you. For the larger sizes the answer is usually freight, which changes the brief: the box needs to survive forklift handling and pallet stacking rather than a parcel conveyor, and the standard 48 x 40 inch pallet footprint becomes a design constraint on its own.
Ordering
Minimum order is 100 boxes, and pricing starts from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before anything prints are included, so a box cut to your exact chassis costs no more to tool than a rounded size. We make in two plants, West Chicago in the US and Guangzhou in China, and turnaround is quoted per product in three lanes: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days plus 2 to 5 for delivery. Specialty imported constructions can run up to about 12 weeks. Rush adds about 7 to 25% depending on the job.
If you are still weighing sizes, the shorter answer is on what size TV box do I need, and the underlying method for any shipper is on sizing a corrugated shipping box.
Send the chassis dimensions, the accessory list and the shipping method through the quote form and we will come back with an internal dimension, a cradle recommendation and a written price.
