Before measuring anything, settle one question: what is actually going in the box. Drones ship in several configurations and each one has a different governing dimension, so a size answer that ignores the configuration is worthless.
Find your shipping scenario
| Scenario | What governs the size | Watch out for |
|---|---|---|
| Folding drone, aircraft only | Folded body plus folded propellers | Props still overhang the body when folded back |
| Fixed-arm drone, aircraft only | Arm span with props removed | Props packed flat need their own shallow area |
| Drone in a hard case | The case, including latches and handle | The case is the product. Ignore the aircraft dimensions |
| Full kit: drone, controller, batteries, charger | Usually the controller or the battery stack | The aircraft is often not the biggest item in its own kit |
| Retail pack that also ships alone | The cushioning, not the contents | One box doing two jobs needs to be designed for both up front |
Two things that are not a size question
The gimbal. It is the most fragile assembly on the aircraft and it needs a cavity that supports the body without loading the gimbal arm. That is an insert design decision, not a box dimension one, and getting it wrong shows up as a damage rate rather than a fit problem.
The batteries. Lithium cells are regulated in transport, and the applicable rules depend on the cell rating, whether the cells are installed or shipped alongside, the transport mode and the carrier. Those rules change and a packaging supplier does not certify your shipment. Confirm the current requirements with your carrier before you finalise the layout. Whatever they turn out to be, give each cell its own cavity so terminals cannot meet.
Do not round up to a stock size
The instinct on a low volume is to take the nearest stock box and fill the gap with void fill. With a light, expensive, dense-value product that is an expensive habit, because parcel carriers bill on the greater of actual and dimensional weight and a drone weighs very little for the space it occupies. Empty volume is the thing you pay for on every shipment. Since the cutting die is included on iBox orders, there is no tooling reason to accept a near-enough size.
What to send with a request
- The three dimensions of the drone in the state it ships
- A list of everything else that goes in the same box
- Whether the box sells at retail, ships alone, or does both
- The insert material you are leaning towards, or a note that you want a recommendation
- Roughly how many cartons per order, so the lane and the pricing can be worked out
Ordering
Minimum order is 100 boxes, with pricing from about $0.48 per unit at bulk volumes confirmed on your written quote. Dies, plates, design support, US shipping and a digital proof are included. Three lanes are available: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days, plus 2 to 5 for delivery, and specialty imported constructions can run up to about 12 weeks. Production is at West Chicago and Guangzhou.
For the full measuring procedure, see how to size a drone box. When you have the component list, send it through the quote form and we will come back with a carton and an insert layout together.
