Custom Apparel Boxes
Clothing has no shape of its own, so the box is set by how the garment is folded, not by the garment. Fold it first and the rest of the specification follows.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the die-cut mailer structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures apparel boxes actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
Fold the garment before you size the box
A folded t-shirt, a folded hoodie and a folded pair of jeans have wildly different thicknesses at the same folded footprint, and the folded stack is what has to fit. Fold the heaviest item in the range the way you will actually pack it, measure the block, and size to that. Working from a flat garment size gives a box that will not close.
The mistake that costs a print run
Leaving the inside of the box blank
The moment the lid comes off is the only time your brand has the customer's full attention, and on a plain box they are looking at bare board. The inside is a separate printable surface with its own dieline. It is the most overlooked surface in the whole pack and most brands throw it away.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom apparel boxes
What size box fits a folded t-shirt?
Around 12 × 9 × 3in for a single folded tee with room for tissue. Hoodies and heavier knits need considerably more depth at the same footprint.
Mailer box or poly mailer for apparel?
A poly mailer is lighter and keeps clothing dry; a mailer box gives a structured unboxing and protects a pressed garment from creasing. Many brands use the box for gifting and premium orders and a mailer otherwise.
Can I print inside an apparel box?
Yes, and it is where the unboxing actually happens. The interior is a separate design surface, and it registers to the outside so the two line up.