Pillow boxes
Pillow Boxes by Size and Proportion
A pillow box is not one shape scaled up and down. The curved end tuck that holds it closed works through a relationship between the panel length and the tuck radius, and that relationship changes as the box grows.
Small boxes need lighter board and a wider tuck. Large ones need heavier board and often an internal support. Square proportions have less closing force than rectangles. None of it is difficult, but a box scaled from the wrong starting point will disappoint, which is why size gets its own set of pages here.
Tell us what goes in the box
Not sure which of these suits your product? Describe it and we will recommend a specification rather than a page.
The full group
Each page covers what that specification does well, where it fails, and what it costs you to choose it.
Large Pillow Boxes
Scaled up for apparel and gift sets, with the board weight to stop it bowing.
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Long Pillow Boxes
Narrow and elongated — for products longer than they are wide.
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Medium Pillow Boxes
The general retail size: big enough to brand properly, small enough to merchandise.
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Small Pillow Boxes
Mini formats for samples, jewelry and favors — down to the limit the tuck allows.
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Square Pillow Boxes
An equal-sided panel — visually distinct, structurally more demanding.
View optionsEvery box is cut to the product
We do not hold a catalog of stock sizes. Each order is die-cut to the dimensions the product needs, which is why we ask for the item itself or its measurements rather than for a size code.
The size pages here describe how the format behaves at different scales, so you know what to expect before we draw a dieline.
How to measure for a quote
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Measure the product at its widest
The actual widest point, including a lid, cap or label that stands proud — not the nominal size.
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Add clearance, not slack
Two to three millimeters per dimension. A pillow box grips by tension, so a snug fit presents better than a generous one.
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Give us the filled weight
It determines the board more directly than the dimensions do.
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Say how it travels
Inside an outer carton, in a mailing bag, or alone through a courier network. These are three different specifications.
By Size: common questions
Do you have standard sizes?
No. Every box is cut to the product, which avoids the compromise of choosing the nearest stock size and paying for space you do not need.
How small can a pillow box be?
Around two inches across before the curved tuck stops holding reliably on standard board. Smaller is possible with a lighter stock and a revised tuck radius.
Why does my large box bow in the middle?
The tuck tension is acting over too long a span for the board weight. A heavier stock, a wider tuck radius, and sometimes an internal pad all counter it.
Should I use one size across a product range?
It reduces cost and stockholding, and it works if the range is dimensionally close. A box sized for the largest item will look loose around the smallest, so there is a limit.
How much clearance should a pillow box size allow?
Add two to three millimeters per dimension, as clearance rather than slack. A pillow box grips by tension, so a snug fit presents the product better than a generous one.
Where should I measure a product for pillow box sizing?
Measure at the actual widest point, including any lid, cap or label that stands proud, rather than using the nominal size. Our pillow box measuring guide covers the detail.
Why do small pillow box sizes need lighter board?
On small boxes, a stiff sheet resists the curve and pushes the tuck back out. Small pillow box sizes work best with lighter board and a wider tuck, while large ones need heavier board.
Are square pillow box sizes harder to make than rectangles?
They are more demanding. Square proportions have less closing force than rectangles, so square pillow boxes need careful attention to the tuck, and a physical sample is worth requesting.
Do large pillow box sizes need internal support?
Often, yes. Large pillow boxes for apparel and gift sets need heavier board to stop the face bowing, and many also benefit from an internal support depending on the contents.
Does the way a pillow box travels change its size specification?
Yes. A pillow box inside an outer carton, in a mailing bag, or alone through a courier network needs three different specifications, so say how it travels when you send the measurements.
Next step
Send us the product, not a box size
Send the product, the quantity and the date you need it on a shelf. We come back with a written quote, a specification and an honest view of anything in the brief that will not work.