Rigid box size calculator
Work out base tray and lid sizes for a two-piece rigid setup box.
How it works
Rigid boxes are made from thick chipboard wrapped in printed or specialty paper. A two-piece box is a base tray with a separate lid that slides over it, so the lid must be sized from the tray's outside, not its inside.
The calculator builds up in layers: product, plus insert on each side and below, gives the tray inside; add chipboard and wrap paper for the tray outside; add a little clearance for the lid inside; then chipboard and wrap again for the finished size. Lids are often shorter than the tray (a partial lid) for easier opening; the lid height here assumes full depth.
Chipboard grade affects both size and feel. 2 mm is the common choice for gift and luxury packaging.
Results are estimates based on typical industry values. Confirm final specifications with your supplier or carrier.
Frequently asked questions
What thickness is rigid box board?
Usually 1.5 to 3 mm chipboard, with 2 mm the most common for gift boxes.
How much bigger should a rigid box lid be?
Just enough to slide over the wrapped base: about 1/32 to 1/16 inch of clearance on each dimension.
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