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Determining folding carton dimensions correctly: product dimension, clearance and inside dimension
Folding carton dimensions start with the product, not the carton. You measure the product, add clearance and obtain the inside dimension from which the construction is derived.
Measuring the product at its largest point
Measure length, width and height at the largest point of each. This includes closure caps, labels, shrink film and anything else that protrudes from the product. For round products such as bottles, the largest diameter counts. Measure several examples, because products made of glass, plastic or textile vary in production. Calculate with the largest measured value. Also determine the orientation in which the product sits in the carton. This determines which product dimension becomes the carton's length, width and height.
Clearance: the space around the product
Clearance is the space between the product and the carton wall. Without clearance, the product is hard to insert and remove. Too much clearance lets it move around inside the carton. How much clearance makes sense depends on product, material and filling. A machine usually needs more space than a hand does. There is no universally valid value. Plan inserts, padding or an information leaflet as separate space requirements and do not count them as clearance.
From product dimension to inside dimension
The inside dimension is the product dimension plus clearance and padding in each direction. It describes the usable space of the assembled carton. You will not find this dimension directly on the drawing: the distance between the crease lines is a different value because of material thickness. Therefore, for every number, note whether it means inside dimension, outside dimension or crease-to-crease dimension, and state the unit. In inquiries, the order also matters. Write out length, width and height instead of giving just three numbers.
Checking with a mock-up
A drawing shows the construction but not the fit. Build a mock-up from the intended material and insert the real product. Check whether it is easy to insert and remove, whether the closure shuts, and whether the product moves when shaken. A paper printout helps you understand the folding sequence. It says little about fit because material thickness is missing. If something does not fit, change the clearance and have the construction recalculated instead of moving individual lines.
How JetDieline calculates
The product fit calculator starts from the product. You enter the product dimension and the desired clearance, and the app suggests the carton dimensions as the inside dimension. The parametric template then recalculates the cut and crease lines. You choose the dimension reference yourself: inside dimension, outside dimension or crease-to-crease dimension. Units are millimetres, centimetres and inches. The check reports when an input makes the construction unusable. You clarify the actual manufacturability with your printer.
Step by step
- Measure the product at its largest point and on several examples.
- Determine the orientation in which the product sits in the carton.
- Add clearance and space for inserts in each direction.
- Record the result as an inside dimension with its unit.
- Build a mock-up from the intended material and check it with the product.
Frequently asked questions
How much clearance does a folding carton need?
That depends on the product, the material and the type of filling. There is no universally valid value. Start with an assumption, build a mock-up and then adjust the clearance accordingly.
Do I give the printer the inside dimension or the outside dimension?
If the product is to fit inside, the inside dimension is the appropriate starting point. If the carton has to fit into a shipping carton or onto a shelf, the outside dimension also matters. Always state the reference explicitly.
Related features
Related terms
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Your product. Your dimensions. Your design.
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