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How to measure your product for custom sized box

When it comes to packaging your soap, dropper, or other cosmetic products, having a box that fits perfectly is essential. Not only does it protect your product, but it also enhances the overall presentation of your brand. If you’re unsure how to measure your product for a custom sized box design, this guide will walk you through the process step by step.

Playful Modern Soap Box Template - Gently Nourish

Why accurate measurements matter

Accurate measurements ensure that your product fits snugly in its packaging, preventing unnecessary movement that could lead to damage. Plus, a well-fitting box looks more professional and creates a better unboxing experience for your customers.

Tools you’ll need

  • A ruler or measuring tape

  • Your product (soap, dropper bottle, etc.)

  • A notebook or digital tool for recording measurements

STEP 1

Measure the dimensions of your product

TIP: for irregularly shaped products, measure the largest dimensions to ensure the box will accommodate the entire product.

STEP 2

Add extra space for comfort

Your box shouldn’t be an exact fit to your product. Adding a small buffer ensures your product slides in easily and has room for any protective materials like tissue paper or padding.

  • Add 3-5 mm (0.11 - 0.19 in) to each measurement for small products like droppers.

  • Add 5-10 mm (0.19 - 0.39 in) for larger or heavier products like soap bars.

STEP 3

Choose the right box style

Pick a box style that matches your product’s needs and packaging goals. Here are some popular options:

Vintage Floral Soap Box Template - Flora Apothecary

  • Foldable boxes: Perfect for lightweight products like soap bars. If you’re using a Cricut machine, you can cut and score a single sheet of cardstock (200-250 gsm) or lightweight cardboard (around 300 gsm). Fold it neatly, and secure the edges for a sturdy design.

  • Rigid boxes: Great for fragile items like glass droppers. For these, use a thicker cardboard (around 400-600 gsm) to provide extra durability. With Cricut, you can cut panels separately and assemble them with glue to create a durable, polished box.

  • Custom inserts: Ideal for products that need to stay firmly in place. Use cardstock (around 200-300 gsm) for lightweight inserts or thicker cardboard for heavier items. Cricut makes it easy to cut inserts that fit snugly around your product, providing extra protection and a professional look.

When using Cricut, check that your design file is compatible, and adjust the material thickness settings to ensure clean, precise cuts. This will help you achieve a professional-looking box with ease.

STEP 4 (optional)

Test your design with a mockup (advanced step!)

You can create a quick test of your box dimensions to ensure accuracy. While this step is optional, if you’re feeling adventurous, you can create a simple mockup preview of your box by referring to the example below:

An example of a box dieline prototype

  1. Draw your template: On paper or lightweight cardboard, carefully draw the dimensions of your box. Use a ruler to ensure straight lines and accurate measurements.

  2. Cut out a template: use paper or lightweight cardboard to cut out the dimensions of your box. Be precise with your ruler and scissors.

  3. Score and fold: lightly score along the lines where you’ll fold. This helps the edges stay clean and sharp.

  4. Assemble the box: use tape or glue to assemble the box shape. If your product is heavy, reinforce the mockup with extra tape.

  5. Check the fit: place your product inside to see how it fits. Ensure there’s enough space for protective materials like tissue paper if needed.

If creating a mockup feels too advanced, don’t worry—it’s not a required step!

STEP 5

Share your measurements for customization

Once you’ve confirmed your measurements, you’re ready to use them for a custom box template or resize an existing one. If you’re buying a premade template, simply provide your dimensions to the designer (that’s me!) to ensure a perfect fit.

Bonus tips for measuring specific products


By following these steps, you’ll create a perfectly fitting box that protects your product and enhances your brand’s presentation. If you have any questions, feel free to reach out or browse my collection of editable box templates designed for cosmetic and skincare businesses.

Need help resizing your box template?

If you’ve found one of my editable box templates that you love but the size doesn’t quite match your product, don’t worry! I can easily resize the box dieline to perfectly fit your needs. All you have to do is send me the exact measurements of your product, and I’ll handle the rest. This way, you can enjoy a beautiful, customized packaging solution without the hassle of starting from scratch!


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