Short answer: take the diagonal, convert it to a real width and height, add the chassis and the cushioning, then check whether the result still ships as a parcel. That last check is the one that changes the design, because the answer is frequently no.
Step one, convert the diagonal
A television's size is its screen diagonal, which is not a dimension of the box. For a 16:9 panel the geometry is fixed: width is the diagonal times about 0.872, height is the diagonal times about 0.490. A 43 inch set is about 37.5 x 21.1 inches of screen. A 65 inch set is about 56.7 x 31.9. Then measure the actual chassis, because the bezel and the rear housing add to those figures and vary by model.
Step two, add what else is in the box
- Panel cradles top and bottom, usually EPS or moulded pulp, which set most of the depth.
- The stand or legs, detached and boxed or trayed separately so hard edges never meet the panel.
- Remote, power cable, mounting hardware, documentation, in a shallow accessory tray.
- A face slip sheet, which adds very little depth and prevents the scratch that turns a unit into a return.
Step three, run the carrier arithmetic
Girth is twice the width plus twice the height. US ground services commonly publish a 165 inch limit on length plus girth and a 108 inch maximum length, with oversize surcharges applying well before those numbers. As an arithmetic illustration using your own measured figures: a box of 52 x 32 x 7 inches gives length plus girth of 130 inches and stays inside the parcel limit, while a box of 70 x 42 x 8 inches gives 170 inches and does not. Do this with your real dimensions and your carrier's current rate card, because it decides whether you are designing a parcel box or a freight box.
What changes if it goes freight
| Parcel | Freight or pallet |
|---|---|
| Designed for conveyor handling and individual drops | Designed for forklift handling and stacking |
| Dimensional weight is the cost driver | Pallet footprint and class are the cost drivers |
| Hand holes matter for the last mile | Cleats, edge protection and stretch wrap matter more |
| One box, one unit | Units per 48 x 40 inch pallet becomes a design constraint |
Two details people miss
Orientation. Flat panels travel on edge, never on the face, so the bottom edge cradle takes the drop energy. Print the orientation instruction clearly, because a box laid flat in a back room and stacked on is the most common damage cause in this category.
The largest model in the range. If you sell several sizes, check whether one die can cover two adjacent models with a different insert. The die is included in the job, so this is an inventory decision rather than a tooling cost decision.
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. We make in West Chicago in the US and Guangzhou in China, with turnaround 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.
The full method, including the panel dimension table, is on how to size a TV box, and the cost arithmetic behind the parcel decision is on dimensional weight.
Send your chassis dimensions, the accessory list and your shipping method through the quote form and we will come back with an internal dimension and a written price.
