Free packaging tools

Free tools for planning packaging

Our tools turn packaging know-how into quick answers. Design a box in 3D and see a live price, download a dieline for your exact size, find the right box size, calculate shipping weight, check box strength and pallet patterns, and test whether your logo is sharp enough to print. Every tool is free, needs no sign-up and runs in your browser. They are the same calculations our packaging specialists use when they prepare quotes, so the answers line up with what you will see in a written quote.

Which tool do I need?

Free tool3D Box BuilderDesign your box in 3D with your logo and see live pricing. Free toolDieline GeneratorDownload print-ready SVG/PDF dielines for 8 box styles. Free toolBox Size FinderFind the right inside and outside box size for your product. Free toolPackaging Cost CalculatorCompare box styles, quantities and options by unit price.

A typical workflow

Most packaging projects follow the same order. The tools fit into each step:

1. Measure the product and find the box size with the Box Size Finder.
2. Check shipping weight for that size with the DIM Weight Calculator; try a slightly smaller size if billable weight jumps.
3. Check strength if boxes will be stacked or palletized, with the Box Strength Calculator.
4. Compare cost for styles, materials and quantities in the Packaging Cost Calculator.
5. Design in 3D and share the look with your team in the 3D Box Builder.
6. Download a dieline for your designer from the Dieline Generator.
7. Check artwork sharpness with the Artwork Checker.
8. Plan pallets for wholesale or warehouse deliveries with the Pallet Calculator.
9. Request a quote with your saved design and specifications.

3D Box Builder

Choose a box style, enter dimensions, pick material, print and finishes, upload your logo and see the box in 3D, rotating and opening. The price updates live as you change options, using the same pricing model as our quotes.

Use it to

• Compare styles side by side before committing.
• Show stakeholders a realistic preview.
• See how print coverage and finishes change the price.
• Save designs to your account and send them with a quote request.

Good to know: the 3D view is a visual guide, not a print proof. Your quote includes a production 3D proof made from your final artwork.

Dieline Generator

A dieline is the flat template of a box with cut and fold lines. Designers place artwork on it so every panel lines up when the box is folded. The generator creates dielines for eight common styles at your exact inside dimensions:

Downloads are SVG (for Illustrator, Affinity Designer, Inkscape, Figma and similar) and 1:1 PDF for printing paper mockups. Layers show cut lines, crease lines, bleed and safe zone.

Good to know: these are accurate templates for design and planning. For production we supply a dieline verified for your exact board and machinery. Need many sizes at once? The Dieline Template Library and E-commerce Dieline Mega Pack have 144 ready-made dielines.

Box Size Finder

Enter your product's dimensions (or the packed set of items) and how much protection it needs. The finder adds clearance for the product and any insert or cushioning, then gives recommended inside dimensions and the approximate outside dimensions for that box style and board.

Why inside dimensions matter: packaging is specified by inside size, the space your product needs. Outside size depends on the board thickness and style, and it is what carriers use for dimensional weight.

Clearance guide

DIM Weight Calculator

Parcel carriers charge for the greater of a package's actual weight and its dimensional (DIM) weight, which converts size into weight.

The formula: DIM weight = length × width × height (outside, in inches, usually rounded to the nearest whole inch) ÷ the carrier's divisor. Common published daily-rate divisors are 139 for UPS and FedEx and 166 for USPS on larger parcels; negotiated contracts can differ.

Example: a 12 × 10 × 6 in box is 720 cubic inches. 720 ÷ 139 ≈ 5.2, which rounds up to 6 lb. If the packed box weighs 3 lb, you pay for 6 lb. A 10 × 8 × 4 in box (320 cubic inches) gives about 2.3 → 3 lb, so the same product could bill at half the weight.

The calculator shows billable weight for several carriers and how much a smaller box would save. For a whole product range, the Box Size & Shipping Cost Optimizer matches every product to the best box. Read more in the box sizing and DIM weight guide.

Box Strength Calculator

Boxes stacked in warehouses and on pallets must carry the weight of everything above them. The calculator estimates box compression strength (BCT) using the simplified McKee formula:

BCT ≈ 5.87 × ECT × √(board caliper × box perimeter)

where ECT is the board's edge crush rating, caliper is board thickness and perimeter is 2 × (length + width), with consistent units.

How to use the result: compare the estimated BCT with the load on the bottom box, multiplied by a safety factor for humidity, time in storage and handling. Real-world strength is reduced by handholes, high-coverage printing, damp conditions, interlocked stacking and pallet overhang, so treat the result as an estimate and validate critical loads with a lab compression test.

Packaging Cost Calculator

Compare unit prices across box styles, sizes, materials, print options, finishes and quantities. It uses the same published pricing model as the rest of our site, so it shows how each decision moves the price.

What it shows clearly

• How unit price falls as quantity rises.
• The cost difference between styles (for example mailer vs. rigid).
• The effect of print coverage, inside printing and finishes.

Good to know: estimates are confirmed in your written quote, which includes your exact specification and delivery address. For total cost, including setup, freight and storage, use the Packaging Budget & Landed-Cost Planner.

Pallet Calculator

Enter carton dimensions and weight, pallet size (48 × 40 in by default) and height and weight limits. The calculator shows cartons per layer in both orientations, number of layers, cartons per pallet, load height and weight, and how well the pallet footprint is used.

Tips

• Cartons should not overhang the pallet edge; overhang weakens them.
• Column stacking is strongest; interlocking adds stability but reduces stacking strength.
• Receivers such as warehouses and marketplaces set their own height, weight and labeling rules.

For case packing and shipment planning, the Pallet & Case Planner adds units per case and pallets per shipment.

Artwork Checker

Upload a logo or image and enter the size it will be printed. The checker calculates the effective resolution: image pixels ÷ printed inches.

Example: a logo 1,200 pixels wide printed 4 in wide is 300 ppi. The same logo printed 8 in wide is 150 ppi. Vector logos (AI, EPS, SVG or vector PDF) stay sharp at any size.

Privacy: the image is analyzed in your browser and is not uploaded to our servers.

How accurate are the tools?

Your data stays private

The Artwork Checker processes images in your browser. Calculators run in your browser and do not store what you enter. 3D designs are saved only if you choose to save them to your account, and you can delete them at any time. See our privacy policy.

Tools for each type of buyer

Tools and the rest of the site

• Products and industries: every product page links to the tools with that style pre-selected where possible. Browse products and industries.
• Guides: the blog explains the decisions behind the numbers.
• Shop: templates, spreadsheets and guides extend the tools for bigger projects.
• Calendar: the US packaging calendar shows when to order for each season.

Common questions the tools answer

"Why is my shipping so expensive?"

Usually dimensional weight. Check your box in the DIM Weight Calculator and try sizes 1 in smaller per side; many brands save a full billable pound or more per order.

"Will this box survive the warehouse?"

Use the Box Strength Calculator with your board grade and stack height, then add a safety factor. If the margin is small, choose a stronger board or column-stack the pallet.

"How many boxes should I order?"

The Cost Calculator shows how unit price changes with quantity. Balance that against cash and storage; the Budget & Landed-Cost Planner compares order quantities on effective cost.

"Is my logo good enough?"

Run it through the Artwork Checker at the size it will print. If it is below 300 ppi for a carton, ask your designer for a vector file.

Tips for getting the most from the tools

1. Measure carefully: use a ruler or calipers and measure the packed product, including anything that wraps it.
2. Think inside dimensions for boxes and outside dimensions for shipping.
3. Try two or three options: small changes in size or style often make big differences in cost and shipping.
4. Save your designs so you can send them with a quote request.
5. Ask us if a result looks surprising; we will check it with you.

How to measure a product correctly

Accurate measurements make every tool more useful:

1. Measure the packed product: include any bottle cap, pump, inner pouch, wrap or retail carton.
2. Measure the three largest dimensions at the widest points, not the label.
3. Use inches to two decimals (or millimeters) with a ruler or calipers.
4. Note the weight of the packed product, including inserts.
5. Group items that ship together and measure them as one block in their packed arrangement.
6. Decide protection: snug for sturdy items, more clearance for fragile ones.

A complete worked example

A candle brand sells an 8 oz candle in a glass jar, about 3.25 in across and 4 in tall, weighing about 1 lb packed.

1. Box Size Finder: with about 1/8 in clearance and a paperboard insert, a mailer around 4 × 4 × 4.5 in inside fits one candle.
2. DIM Weight Calculator: outside dimensions of about 5 × 5 × 5 in give 125 cubic inches, well under one cubic foot, so billable weight is close to actual weight.
3. Box Strength Calculator: shipped in cases of 12 and stacked in a warehouse, the case needs enough compression strength for the stack height with a safety factor; the calculator suggests whether a 32 ECT single wall is sufficient.
4. Packaging Cost Calculator: comparing 500, 1,000 and 2,500 mailers shows how unit price falls with quantity.
5. 3D Box Builder: the brand tests kraft vs. white board and a one-color vs. full-color print.
6. Dieline Generator: the designer downloads a dieline for the chosen size.
7. Artwork Checker: the logo is checked at its printed width.
8. Pallet Calculator: cases of 12 are planned on a 48 × 40 in pallet for a retailer delivery.

The numbers here are illustrative; run your own product through each tool.

Understanding the results

Inside vs. outside dimensions

Inside dimensions are what the product needs. Outside dimensions add board thickness and construction allowances; carriers bill on outside dimensions.

Billable weight

The larger of actual weight and DIM weight, each rounded up to the next pound for most US parcel services.

Compression strength

An estimate of the top load a box can withstand before collapsing in a laboratory test. Real stacks need a safety margin above the actual load.

Unit price

The price per box at a given quantity, before freight unless stated. Use landed cost (including setup and freight) to compare suppliers.

Effective resolution

How many image pixels fall in each printed inch. Higher is sharper; vector artwork has no resolution limit.

Limitations to keep in mind

• Tools give planning answers; written quotes and production proofs confirm details.
• Carrier rules change; check divisors and thresholds against your carrier account.
• Strength estimates do not include every real-world factor.
• Pallet results assume simple column patterns; receivers may have extra rules.
• Prices depend on final artwork, specification and delivery address.

Tool glossary

Suggest a tool

If a calculation would help your packaging decisions and we do not have a tool for it yet, tell us through the contact page. Many of our tools started as questions from customers.

Dieline styles explained

Mailer box (roll-end tuck front)

Folds from a single sheet with double side walls and a tuck-in lid. Strong, easy to assemble without tape and ideal for inside printing.

Shipping box (RSC)

The regular slotted container: four flaps on top and bottom that meet in the middle. The most material-efficient corrugated box.

Reverse and straight tuck end

Paperboard cartons with tuck flaps at both ends. Reverse tuck has the flaps on opposite sides; straight tuck has both on the same side, which gives a cleaner front panel.

Auto-lock bottom

A carton whose bottom locks into place when the box is opened, supporting heavier products while keeping a tuck top.

Four-corner tray

A tray with glued or locked corners, used as a base, lid or display tray.

Sleeve

A tube of board that slides over a tray or box, carrying most of the branding.

Pillow box

A curved box that closes with curved end flaps; popular for small gifts and accessories.

Ways to reduce DIM weight

1. Right-size the box so the product fills it with sensible clearance.
2. Use mailers for soft goods instead of rigid boxes.
3. Reduce the tallest dimension: lying a product flat often helps.
4. Standardize a small set of sizes that fit most orders well.
5. Use inserts instead of void fill to keep products away from walls in smaller boxes.
6. Check carrier thresholds, such as size limits above which DIM pricing or surcharges apply.

The Box Size & Shipping Cost Optimizer runs these comparisons across your whole product range.

Safety factors for box strength

A box in a real warehouse needs more strength than the load on it, because conditions reduce performance. Planners commonly multiply the expected top load by a safety factor:

Ask your packaging supplier which safety factor they recommend for your supply chain, and test critical loads.

Pallet patterns at a glance

Accessibility and ease of use

Our tools are built to be usable with keyboards and screen readers where possible, with clear labels, visible focus states and results in plain text. If any tool is hard to use with your setup, please tell us through the contact page and see our accessibility statement.

From tools to production

Tool results feed directly into a quote:

1. Save your 3D design or note sizes and options.
2. Send them through the quote form with your artwork status.
3. Receive a written quote with landed pricing.
4. Approve a production dieline and 3D proof.
5. Production, quality checks and delivery.

The how it works page walks through each step and typical timelines.

Tool walkthroughs for common situations

"I'm launching my first product"

Start with the Box Size Finder to get inside dimensions, then use the Packaging Cost Calculator to compare two or three styles at 250, 500 and 1,000 units. Build your favorite in the 3D Box Builder, download its dieline for your designer, and check your logo in the Artwork Checker. Save the design and request a quote.

"Shipping costs are eating my margin"

List your best-selling products and the boxes you use. For each, run the DIM Weight Calculator with your current box, then with a box one size smaller (or a mailer instead of a box). Where billable weight drops, check the new size fits in the Box Size Finder. For a whole catalog, the Box Size & Shipping Cost Optimizer does this for 20 products at once.

"A retailer wants pallets"

Use the Box Strength Calculator to confirm your case board can handle the stack height, then the Pallet Calculator for cases per layer, layers and load height within the retailer's limits. Check their labeling and wrapping rules before shipping.

"My designer needs templates for several sizes"

Generate each size in the Dieline Generator, or download the Dieline Template Library and E-commerce Dieline Mega Pack for 144 ready-made sizes.

"I'm comparing quotes from different suppliers"

Use the Packaging Cost Calculator as a reference point for the same specification, then compare suppliers on landed cost, lead time and quality with the Packaging Supplier Scorecard.

"My logo looks blurry on the proof"

Run the image through the Artwork Checker at its printed size. If it is below 300 ppi for a carton, ask for a vector version of the logo (AI, EPS, SVG or vector PDF) or a larger original image.

Formulas reference

Inputs and outputs for each tool

Common mistakes the tools help you avoid

Tips for designers using our dielines

• Keep the dieline on its own layer, locked, set to overprint and never printed.
• Place artwork on a layer below the dieline and extend backgrounds to the bleed.
• Check orientation: some panels must be upside down on the flat sheet to read correctly when folded.
• Mark finish areas (foil, spot UV, emboss) on separate layers.
• Print the PDF at 100% and fold a paper mockup before sending final files.

Planning a packaging project in ten days

Behind the calculations

We aim to make every tool's assumptions clear:

• Rounding: carriers commonly round each package dimension to the nearest whole inch and round weights up to the next pound; the DIM Weight Calculator follows that convention.
• Board allowances: outside dimensions add board thickness and construction allowances that differ by style and material.
• Clearance: the Box Size Finder adds clearance by protection level; fragile products in cushioning need more.
• Strength: the McKee formula estimates compression strength of regular slotted containers in good condition; other styles, cut-outs and damp conditions change real results.
• Pricing: estimates use our published pricing model by style, size, material, options and quantity; freight is quoted separately for your address.
• Pallets: calculations use simple column patterns and the limits you enter; check receiver rules.
• Resolution: effective resolution is pixel width divided by printed width; it is exact for raster images.

If a result looks surprising, send us the inputs through the contact page and we will check it with you.

How the tools are maintained

We build and maintain the tools using the same methods we use to specify boxes for customers. We review formulas, carrier divisors and price models periodically and update the tools when standards or our pricing change. If you notice a result that does not match your carrier bill or a quote, tell us: real-world feedback helps us keep the tools accurate for everyone.

Key takeaways

• Size boxes by inside dimensions; carriers bill on outside dimensions.
• Small size changes can cut a full billable pound from every shipment.
• Strength estimates need a safety margin for real warehouse conditions.
• Compare quantities and total landed cost, not just unit price.
• Dielines from the generator are accurate for design; production dielines are confirmed with your quote.
• Vector logos stay sharp at any size; check raster images at their printed size.

Learn more

• Custom packaging guide
• Box styles guide
• Box sizing and DIM weight guide
• Packaging artwork and dieline guide
• Custom packaging cost guide