Box-in-box calculator
Size the outer carton when you double box a fragile item.
How it works
Double boxing, or box-in-box, is the most reliable way to ship very fragile or valuable items. The product is packed snugly in an inner box, which then floats inside a larger outer box with cushioning on every side. Shocks are absorbed by the outer layer before they reach the product.
Enter the outside dimensions of the inner box. Carriers commonly recommend at least 2 inches (5 cm) of cushioning between the two boxes. The trade-off is size: double boxing adds 4 inches or more to each dimension, so check the dimensional weight before settling on it.
Results are estimates based on typical industry values. Confirm final specifications with your supplier or carrier.
Frequently asked questions
How much space should be between boxes when double boxing?
At least 2 inches (5 cm) on every side, filled with cushioning such as foam, air pillows or crumpled paper.
When is double boxing worth it?
For glass, ceramics, electronics and anything expensive or irreplaceable. For durable goods, a single right-sized box is cheaper.
More box sizing and design tools
- Box dimensions converter
Convert a box size between inches, centimeters, millimeters and feet in one step, including fractional inches.
- Inside to outside dimensions calculator
Turn a box's inside dimensions into its outside size, based on the board it's made from.
- Outside to inside dimensions calculator
Measured the outside of a box? Find the usable space inside it.
- Box surface area calculator
Find a box's outer surface area and how much corrugated board it takes to make.
- RSC blank size calculator
Get the flat sheet size, panels and flap depth for a regular slotted corrugated box.
- Tuck end box blank size calculator
Estimate the flat blank of a reverse tuck end carton and how many fit on a press sheet.