Underwear packaging is a soft goods problem, which means the box is sized by folding technique rather than by product dimensions. Two brands with identical garments will need different boxes if one folds in thirds and the other folds in quarters. Settle the fold before you settle the box.
Fold first, then measure
- Fold one garment the way your fulfilment team will actually fold it, every time, on the day. Not the way it looks best in a photo.
- Measure the folded footprint, length and width, with the garment relaxed rather than pressed.
- Measure the folded thickness. Stack the pack count if it is a multipack, put a light hand pressure on it, and measure again. That compressed height is your working depth.
- Repeat all of the above with the largest size you sell. That is the measurement that goes on the quote.
If the garment is bagged in poly before it goes in the box, measure it bagged. A poly bag adds little thickness and a lot of width if it is oversized.
Size range is the hidden variable
A range running from XS to 3XL can vary by an inch or more in folded footprint. You have three honest options:
| Approach | Effect | When it makes sense |
|---|---|---|
| One box sized to the largest garment | Simplest inventory, smaller sizes sit loose | Most brands, most of the time |
| Two box sizes, split at a break point | Tighter fit, two SKUs to manage | Wide ranges or premium presentation |
| Flexible format such as a sleeve or a band | Accommodates variance without a rigid cavity | Minimalist retail programmes |
Format follows channel
Where the pack is sold changes its shape before it changes its size. On a shelf or a peg, the face panel and the hang hole matter and the depth can be shallow. In a self shipped ecommerce parcel, the box needs to survive a parcel network on its own, which means corrugated rather than folding carton, or a carton inside a mailer. In a multipack going into a retailer's case, the unit box external dimension has to multiply cleanly into the case.
A window is common in this category so the fabric and colour are visible. Decide on it at design stage, because the window die is cut with the carton die.
Board and print
Folding carton board gives the crisp fold and print surface most underwear brands want. Kraft board reads more natural and takes one or two colour print well. If the pack ships alone, step up to a printed corrugated mailer in E flute, which is about 1/16 in per wall and still prints cleanly.
Ordering, minimum and turnaround
Minimum order is 100 boxes, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die and plates are included along with design support, US shipping and a digital proof before anything prints, so the box can be cut to your fold rather than to a stock carton. If you later change the fold pattern, you will need a new die, which is a good reason to settle the fold with your fulfilment team before ordering.
Turnaround runs in three lanes: rush (expedited production with air freight), standard (air) and cost saver (sea), from about 7 business days plus 2 to 5 for delivery, with specialty imported items up to about 12 weeks. Rush carries a premium of about 7 to 25% depending on the job. We produce in West Chicago and Guangzhou. To order, see custom underwear boxes.
Fold the largest garment you sell, measure it, stack your pack count, and request a quote with those three numbers. If you are between two formats, ask for both on the same quote and compare the landed cost per unit.
