Start with what is in the pack, then with where it sells. Those two answers between them produce a size, and almost every mistake in this category comes from skipping the second one.
Pick your approach
| Approach | Works when | Cost of it |
|---|---|---|
| One carton for the whole range | Cases across models are close in size | Looks loose on the smallest models, more void fill |
| A carton per model | You want a proper fit and a premium feel | More SKUs to hold, forecast and store |
| Two sizes, small and large | Your range splits naturally by device size | The usual compromise, and usually the right one |
| Hanging pack | Peg wall retail and accessory shops | Tab placement and pack rigidity become design constraints |
Questions to answer before ordering
What else is in the box?
A screen protector, a cleaning cloth, a card, an applicator frame. Each adds thickness, and the thickness of the filled pack is what the carrier measures and what the peg hook has to hold.
Closed, or with a window?
A closed carton gives you the whole surface for artwork and hides the product. A window shows the case colour, which matters in shops where customers are matching a case to a device they are holding. The window needs a margin of board around it to keep the panel stiff, and the film is a separate line on the spec.
How long will the artwork live?
Device models turn over fast. If the model name is printed large across the front, the artwork dies with the device. Keeping model identification in a small isolated area, or on an applied label, lets one carton design survive several device generations.
Does it ship on its own?
A carton that sits inside a retailer's outer is protected by that outer. A carton posted directly to a customer is not, and a thin folding carton arrives bent. If you sell direct, either move to E flute corrugated at about 1/16 inch caliper or plan a mailer around the retail carton and allow for its board thickness in the sizing.
Common mistakes
- Sizing from published phone dimensions instead of the actual case.
- Forgetting the camera bump, which is often the thickest point of the pack.
- Ordering a hanging pack without checking that the filled pack hangs level.
- Accepting an external dimension on the quote when you needed an internal one.
Minimum, price and lead time
The minimum is 100 boxes. Pricing runs from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Turnaround is quoted per product across three lanes: rush, which is expedited production plus air freight at a premium of roughly 7 to 25 percent depending on the job, standard on air, and cost saver on sea, from about 7 business days in production plus 2 to 5 days for delivery. The cutting die, the plates, design support, US shipping and a digital proof are included.
The measuring method, step by step, is in how to size a phone case box. To order, see cell phone accessories packaging, or send a measured case with a quote request and we will size the carton around it.
