Enter your product size and let the tool size the carton for the best pallet load.
The Carton Box Designer turns a product size into a finished carton specification. Enter the dimensions of one product (the inbox), and the tool works out the carton inner size, adds the flute allowance to get the outer size, draws the RSC dieline, and simulates how those cartons stack on a pallet. With Max Load enabled it searches every arrangement and picks the one that puts the most units on a single pallet without exceeding your carton weight limit. No install or sign-up, and the result can be saved as a PDF report or a dieline PDF.
| Flute | Thickness | Typical use |
|---|---|---|
| B-Flute | 3.0 mm | Retail boxes, light goods, good printability |
| A-Flute | 5.0 mm | General shipping cartons, good cushioning |
| AB-Flute (double wall) | 8.0 mm | Heavy or stacked loads, export cartons |
The inner size is the product size multiplied by the arrangement plus a clearance gap on every side: inner length = product length × count + (count + 1) × gap. The outer size then adds the flute allowance, because corrugated board has real thickness and the box bulges slightly once assembled. A-flute adds roughly 6 mm to length and width and 9 mm to height.
B-flute is about 3 mm thick with a fine profile — it prints well and suits retail packaging. A-flute is about 5 mm and gives more cushioning and stacking strength, so it is the usual choice for shipping cartons. AB-flute is a double wall around 8 mm, used for heavy contents or tall stacks where compression strength matters most.
Two limits decide it: the carton weight and the pallet footprint. Manual handling guidance generally keeps a carton under about 15 kg. Beyond that, a carton that divides neatly into the pallet gives a better load — which is exactly what the Max Load option searches for, testing every arrangement that stays under your weight limit.
RSC stands for Regular Slotted Container, the most common corrugated box. It is made from one blank: four side panels plus a glue tab, with flaps top and bottom. Each flap is half the box width, so the two outer flaps meet in the middle when closed. The dieline this tool draws is an RSC blank, with cut lines in red and crease (fold) lines in blue.
A carton only loads well if its footprint divides into the pallet with little waste. On a 1,100 × 1,100 mm pallet, a carton of 550 × 366 mm tiles almost perfectly, while one a few millimetres larger can drop a whole row and lose 10% or more. Because the carton size follows from the arrangement, changing how many products go in each carton is usually the fastest way to raise the load.
Products are never exactly their nominal size — labels, seams and slight bulging all add a little. Leaving a 2–3 mm gap around each product prevents the case where everything fits on paper but not on the packing line. The gap is included when the carton size is calculated, so it flows through to the outer size and the pallet load.