{"id":4757,"date":"2026-08-07T20:32:33","date_gmt":"2026-08-07T10:32:33","guid":{"rendered":"https:\/\/printshop.paperlust.co\/blog\/?p=4757"},"modified":"2026-08-07T20:33:41","modified_gmt":"2026-08-07T10:33:41","slug":"mailer-box-sizes-australia","status":"publish","type":"post","link":"https:\/\/printshop.paperlust.co\/blog\/mailer-box-sizes-australia","title":{"rendered":"Mailer Box Sizes in Australia: How to Choose the Right One"},"content":{"rendered":"<style>\n#post-4757 .entry-content p { font-size:20px; line-height:1.7; }\n#post-4757 .entry-content h2 { font-size:34px; line-height:1.3; text-transform:none; margin-top:48px; }\n#post-4757 .entry-content h3 { font-size:24px; line-height:1.35; text-transform:none; margin-top:32px; }\n#post-4757 .entry-content ul, #post-4757 .entry-content ol { font-size:20px; line-height:1.7; }\n#post-4757 .entry-content table { font-size:16px; line-height:1.5; }\n#post-4757 .entry-content figure.pl-fig { margin:34px 0; }\n@media (max-width:768px) {\n  #post-4757 .entry-content p,\n  #post-4757 .entry-content ul,\n  #post-4757 .entry-content ol { font-size:18px; }\n  #post-4757 .entry-content table { font-size:14px; }\n}\n<\/style>\n<p>Choosing the wrong mailer box size is a surprisingly costly mistake. A box that is too small forces the lid to dome and risks the contents shifting or arriving damaged. A box that is too large needs void fill to stop things moving, adds cubic weight to every parcel, and tells the customer you are not paying attention. Getting the size right is one of the simplest ways to control your shipping costs and keep your unboxing experience consistent.<\/p>\n<p>The measurement process is straightforward: you need to know what your packed product measures, not your bare product. That includes tissue, padding, inserts, and anything else that goes in the box. Once you have those three dimensions, you add clearance and choose the closest size above your threshold. This article gives you the exact process and the full dimension table for both our ranges.<\/p>\n<p>One thing to note before you get to the table: both our full-colour and kraft mailer box ranges share the same Small size, but their Medium and Large sizes are different. Most suppliers do not make this clear. If you are comparing the two ranges or planning to switch between them at a later volume, check the dimensions for the size you need in each range before you commit.<\/p>\n<div class=\"cheat-sheet\" style=\"background:#f8f6f3;border-left:4px solid #c9a96e;padding:20px 24px;margin:28px 0;\">\n<p><strong>The short version<\/strong><\/p>\n<ul>\n<li>Measure your product as it will be packed, including tissue and padding, then add 15 to 25mm of clearance on each side. That is your minimum internal size.<\/li>\n<li>Both ranges share the Small: 265 x 200 x 90mm. It suits a folded tee, a candle, a small cosmetics set, or a single-product gift.<\/li>\n<li>The Medium and Large sizes differ between full-colour and kraft. Full-colour Medium is 310 x 240 x 110mm; kraft Medium is 300 x 230 x 115mm.<\/li>\n<li>Full-colour Large is 425 x 295 x 110mm; kraft Large is 400 x 270 x 90mm. The kraft Large is shallower than the kraft Medium.<\/li>\n<li>An oversized box adds void fill cost and can push your parcel into a higher cubic weight band with most Australian carriers.<\/li>\n<li>Custom sizes are available on request for both ranges if none of the three standard sizes work for your product.<\/li>\n<\/ul>\n<\/div>\n<h2>How to measure your product for a mailer box<\/h2>\n<p>The most common sizing error is measuring the bare product. You need to measure the product as it will actually ship: wrapped in tissue, nested in any padding, with inserts and cards in place. Pack a real sample and measure the bundle, not the item on its own.<\/p>\n<p>Take three measurements: length (the longest horizontal dimension), width (the shorter horizontal dimension), and height (how tall the stack sits when the bundle is lying flat). Write those down before you consult the size table.<\/p>\n<p>Next, add your clearance. The guidance on both our mailer box product pages is to allow roughly 15 to 25mm of clearance on each side. Fifteen millimetres per side is snug and assumes firm, well-placed void fill. Twenty-five millimetres per side is more comfortable and accommodates a tissue wrap, a crinkle layer, and a fold-over card. If your product is fragile or irregularly shaped, err toward the higher end.<\/p>\n<p>Apply the clearance to all three dimensions. A product that packs to 240 x 175 x 65mm needs at least 270 x 205 x 95mm of internal space. That rules out the Small (265 x 200 x 90mm) because the height is marginal, and puts you into Medium territory for both ranges. Running through this calculation before you look at the table saves a lot of second-guessing later.<\/p>\n<h2>Small mailer box: 265 x 200 x 90mm<\/h2>\n<p>The Small is the one size that is consistent across both ranges: 265mm long, 200mm wide, and 90mm deep. If you are weighing up print methods and want to know that the box dimensions will be identical regardless of which range you choose, the Small is the straightforward choice.<\/p>\n<p>The constraint to watch is the 90mm height. With 15 to 25mm of clearance per side, your product needs to pack to no more than about 40 to 60mm in height. That covers a folded tee shirt, a single scented candle, a small cosmetics set, a jewellery box, or a single-product launch gift. If you are packing two items on top of each other or including a tissue layer that adds meaningful height, measure the bundle rather than estimating.<\/p>\n<p>For subscription box operators, the Small works well when everything fits in one layer and the items are compact. The moment you need a tray insert or a second layer, pack a real sample and measure before moving up a size.<\/p>\n<h2>Medium mailer box: where the two ranges diverge<\/h2>\n<p>This is the size where the two ranges part ways, and where most buyers run into trouble if they are not aware of the difference.<\/p>\n<p>The full-colour Medium is 310 x 240 x 110mm. The kraft Medium is 300 x 230 x 115mm. The kraft version is 10mm shorter in length and 10mm narrower in width, but it is 5mm taller. For a product sitting comfortably inside either footprint, this distinction rarely matters in practice. For a product that is borderline on length or width, it can determine which range works.<\/p>\n<p>A hardback book that measures 280 x 210mm as packed has 30mm of spare length and 30mm of spare width in the full-colour Medium. The same book in the kraft Medium has 20mm of spare length and only 20mm of spare width, but an extra 5mm of headroom in height. Neither is wrong for a well-padded pack. But if your product is flat and wide, the full-colour Medium&#8217;s extra 10mm in each horizontal dimension may be the better fit.<\/p>\n<p>Both Mediums suit a skincare kit, a book, a mid-range gift hamper, or a standard monthly subscription box.<\/p>\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" data-src=\"https:\/\/printshop.paperlust.co\/blog\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1.jpg\" alt=\"Overhead shot of an open full-colour mailer box with botanical design and skincare products wrapped in tissue, squared beside a kraft mailer box with landscape imagery on a pale timber surface.\" class=\"wp-image-4790 lazyload\" width=\"1536\" height=\"1024\" data-srcset=\"https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1.jpg 1536w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1-300x200.jpg 300w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1-1024x683.jpg 1024w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1-768x512.jpg 768w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1-650x433.jpg 650w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-1-624x416.jpg 624w\" data-sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" style=\"--smush-placeholder-width: 1536px; --smush-placeholder-aspect-ratio: 1536\/1024;\" \/><figcaption class=\"wp-element-caption\">Two boxes on the same footprint, one printed in full colour and one left as natural kraft.<\/figcaption><\/figure>\n<h2>Large mailer box: a wider difference than you might expect<\/h2>\n<p>The two Large sizes are further apart than the two Mediums, and the distinction matters more.<\/p>\n<p>The full-colour Large is 425 x 295 x 110mm. The kraft Large is 400 x 270 x 90mm. That is a 25mm difference in length, a 25mm difference in width, and a 20mm difference in height. If you are planning to order the Large, confirm which range you are working with and check your packed product against those specific numbers.<\/p>\n<p>One detail worth highlighting: the kraft Large (90mm deep) has the same height as the kraft Small. It is actually shallower than the kraft Medium (115mm). This is not a misprint. The kraft Large is designed for flat, wide items such as stacked folded garments, large scarves, flat apparel bundles, or wide flat gifts that need floor area but not much depth. A pair of rolled jeans with tissue will likely sit at around 60 to 70mm of stacked height and close cleanly. If your product packs to more than about 65mm of height before adding clearance, the kraft Large will not close without forcing the lid, and you should look at a custom size.<\/p>\n<p>The full-colour Large, at 110mm deep, matches the full-colour Medium in height while offering a much larger footprint. It suits shoes (most shoe boxes sit around 310 to 380mm in length), larger hampers, apparel bundles where items are folded thick, or corporate gifting sets with multiple items stacked.<\/p>\n<h2>All six sizes: a complete comparison<\/h2>\n<p>The table below lists every internal dimension for both ranges. These are internal measurements: the usable space inside the box once assembled. External dimensions are slightly larger due to board thickness, and it is the assembled external dimensions you should use for any carrier cubic weight calculations.<\/p>\n<table style=\"width:100%;border-collapse:collapse;margin:24px 0;\">\n<thead>\n<tr style=\"background:#1a1a1a;color:#fff;\">\n<th style=\"padding:11px 16px;text-align:left;\">Size<\/th>\n<th style=\"padding:11px 16px;text-align:left;\">Range<\/th>\n<th style=\"padding:11px 16px;text-align:left;\">Internal dimensions (L x W x H)<\/th>\n<th style=\"padding:11px 16px;text-align:left;\">Suits<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr style=\"background:#f9f9f9;\">\n<td style=\"padding:11px 16px;\">Small<\/td>\n<td style=\"padding:11px 16px;\">Full-colour<\/td>\n<td style=\"padding:11px 16px;\">265 x 200 x 90mm<\/td>\n<td style=\"padding:11px 16px;\">Folded tee, candle, small cosmetics set, single-product gift<\/td>\n<\/tr>\n<tr style=\"background:#fff;\">\n<td style=\"padding:11px 16px;\">Small<\/td>\n<td style=\"padding:11px 16px;\">Kraft<\/td>\n<td style=\"padding:11px 16px;\">265 x 200 x 90mm<\/td>\n<td style=\"padding:11px 16px;\">Folded tee, candle, small cosmetics set, single-product gift<\/td>\n<\/tr>\n<tr style=\"background:#f9f9f9;\">\n<td style=\"padding:11px 16px;\">Medium<\/td>\n<td style=\"padding:11px 16px;\">Full-colour<\/td>\n<td style=\"padding:11px 16px;\">310 x 240 x 110mm<\/td>\n<td style=\"padding:11px 16px;\">Skincare kit, book, standard subscription box<\/td>\n<\/tr>\n<tr style=\"background:#fff;\">\n<td style=\"padding:11px 16px;\">Medium<\/td>\n<td style=\"padding:11px 16px;\">Kraft<\/td>\n<td style=\"padding:11px 16px;\">300 x 230 x 115mm<\/td>\n<td style=\"padding:11px 16px;\">Skincare kit, book, standard subscription box<\/td>\n<\/tr>\n<tr style=\"background:#f9f9f9;\">\n<td style=\"padding:11px 16px;\">Large<\/td>\n<td style=\"padding:11px 16px;\">Full-colour<\/td>\n<td style=\"padding:11px 16px;\">425 x 295 x 110mm<\/td>\n<td style=\"padding:11px 16px;\">Shoes, apparel bundles, larger hampers, corporate gifting<\/td>\n<\/tr>\n<tr style=\"background:#fff;\">\n<td style=\"padding:11px 16px;\">Large<\/td>\n<td style=\"padding:11px 16px;\">Kraft<\/td>\n<td style=\"padding:11px 16px;\">400 x 270 x 90mm<\/td>\n<td style=\"padding:11px 16px;\">Flat apparel, stacked garments, wide flat gifts<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" data-src=\"https:\/\/printshop.paperlust.co\/blog\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2.jpg\" alt=\"Six corrugated mailer boxes in two-by-three grid on clean white surface photographed from directly above, left column smooth white exterior and right column natural brown kraft, rows stepping up clearly in footprint, all open showing corrugation.\" class=\"wp-image-4791 lazyload\" width=\"1536\" height=\"1024\" data-srcset=\"https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2.jpg 1536w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2-300x200.jpg 300w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2-1024x683.jpg 1024w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2-768x512.jpg 768w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2-650x433.jpg 650w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-2-624x416.jpg 624w\" data-sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" style=\"--smush-placeholder-width: 1536px; --smush-placeholder-aspect-ratio: 1536\/1024;\" \/><figcaption class=\"wp-element-caption\">The full size range laid out together, so the step between each one is easy to see.<\/figcaption><\/figure>\n<h2>The cost of getting the size wrong<\/h2>\n<p>The box itself is a small cost item. What costs you when the size is wrong is everything downstream.<\/p>\n<p>An oversized box needs void fill to stop the contents shifting in transit. Tissue, paper shred, and padded inserts are not expensive per pack, but they add material cost and packing time to every single order. For a business shipping a hundred or two hundred units a month, the difference between a well-fitted pack and one with a large air gap can add meaningfully to your cost per shipment when compounded across a year.<\/p>\n<p>The freight impact is more significant. Most Australian carriers calculate parcel pricing based on cubic weight above a certain threshold. Cubic weight is derived from the assembled external dimensions of your box, not the product weight. A box that is 30mm too long and 30mm too wide in each direction may push your parcel from one weight band into the next, adding a surcharge to every shipment. Since the box repeats with every order, that surcharge compounds over time.<\/p>\n<p>The target is not to squeeze the box so tightly that your product is at risk of damage. The 15 to 25mm clearance guidance exists to ensure the product arrives safely. The goal is to land within that clearance band, not to exceed it by 80mm. For a detailed look at how size drives per-box cost at different quantities, the article on <a href=\"https:\/\/printshop.paperlust.co\/blog\/custom-mailer-box-cost-australia\">what custom mailer boxes cost<\/a> covers the mechanics across both ranges.<\/p>\n<h2>Flat-packed delivery and why it matters for your maths<\/h2>\n<p>Both the full-colour and kraft ranges arrive to you flat-packed. The boxes are delivered as flat sheets and fold up in seconds without tape or glue, locking via the roll end tuck front closure. For a carrier sending assembled boxes, this distinction does not exist. For you as the buyer, it changes your economics.<\/p>\n<p>When flat-packed boxes travel from the printer to your warehouse or home studio, the carrier charges freight on the flat stack, not on the assembled volume. A stack of two hundred flat mailer boxes takes up a fraction of the space that two hundred assembled boxes would. This makes ordering in volume far more practical from a storage standpoint: a Large box that would be unwieldy to store assembled sits neatly in a flat stack beside everything else.<\/p>\n<p>For your outbound shipments, the box assembles quickly at the packing bench. The front tuck flap lets the customer open and reseal cleanly, which is useful for subscription businesses and for products that may need to be returned. Once assembled and packed, apply a strip of tape across the front flap to secure the closure through transit. Use the assembled external dimensions when calculating carrier cubic weight for your cost model.<\/p>\n<p>If you are working out the unit economics for your packaging spend, the article on <a href=\"https:\/\/printshop.paperlust.co\/blog\/budget-packaging-hub\">packaging on a budget<\/a> covers how flat-pack pricing, inbound freight, and void fill all fit together across the range.<\/p>\n<h2>Full-colour or kraft: how print method shapes your size options<\/h2>\n<p>The choice between full-colour and kraft is usually driven by brand fit. But it also determines which Medium and Large dimensions you are working with, so it is worth settling before you finalise a size.<\/p>\n<p>Full-colour mailer boxes print edge to edge in CMYK on all exterior panels, on a smooth white liner. Logos, photography, gradients, and brand colour fields all reproduce sharply. This range is available in small batches from 10 units on the digital press, and moves to offset printing at 500 and 1,000 units where the per-box economics change substantially. The full-colour Medium is 310 x 240 x 110mm and the Large is 425 x 295 x 110mm.<\/p>\n<p>Kraft mailer boxes use natural unbleached brown board, printed in one or two spot colours by flexographic printing. They suit logos, wordmarks, and clean line art. The board tone is part of the aesthetic: a single-colour logo in black, forest green, or terracotta reads as intentional on natural kraft rather than as a budget limitation. The minimum quantity is 500 units. The kraft Medium is 300 x 230 x 115mm and the Large is 400 x 270 x 90mm.<\/p>\n<p>If you are launching with a small batch on the full-colour range and plan to move to kraft at volume, check your product against the kraft dimensions before committing to that path. A product that fits the full-colour Large with room to spare may need a custom size in the kraft range. For a deeper look at the structural and aesthetic differences between the two options, see the guide to <a href=\"https:\/\/printshop.paperlust.co\/blog\/mailer-box-styles-explained\">mailer box styles<\/a>. To compare both ranges and get started, browse <a href=\"https:\/\/printshop.paperlust.co\/categories\/mailer-boxes\">custom mailer boxes in Australia<\/a>.<\/p>\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" data-src=\"https:\/\/printshop.paperlust.co\/blog\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3.jpg\" alt=\"Side-by-side close-up of full-colour mailer box with vibrant CMYK abstract branding and text next to kraft box with single-colour wordmark, both Medium size open to show interior depth, photographed from front at slight angle with hands holding.\" class=\"wp-image-4792 lazyload\" width=\"1536\" height=\"1024\" data-srcset=\"https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3.jpg 1536w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3-300x200.jpg 300w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3-1024x683.jpg 1024w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3-768x512.jpg 768w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3-650x433.jpg 650w, https:\/\/blog.printshop.paperlust.co\/wp-content\/uploads\/2026\/08\/mailer-box-sizes-australia-3-624x416.jpg 624w\" data-sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" style=\"--smush-placeholder-width: 1536px; --smush-placeholder-aspect-ratio: 1536\/1024;\" \/><figcaption class=\"wp-element-caption\">Full colour print on a white liner beside a single colour mark on kraft board.<\/figcaption><\/figure>\n<h2>Frequently asked questions<\/h2>\n<h3>What are the standard mailer box sizes in Australia?<\/h3>\n<p>There is no single national standard; each supplier sets their own range. Our full-colour and kraft mailer boxes each come in three sizes. The Small (265 x 200 x 90mm) is the same in both ranges. The Medium and Large differ: full-colour Medium is 310 x 240 x 110mm, kraft Medium is 300 x 230 x 115mm; full-colour Large is 425 x 295 x 110mm, kraft Large is 400 x 270 x 90mm. All are internal dimensions. Custom sizes are available on request.<\/p>\n<h3>What size mailer box do I need for a T-shirt?<\/h3>\n<p>A folded adult tee typically packs to around 230 to 250mm x 160 to 180mm x 20 to 30mm, depending on how tightly it is folded. Adding 15 to 25mm clearance per side puts you comfortably inside the Small (265 x 200 x 90mm). If you are sending two tees or adding a tissue layer that builds height, pack the actual bundle and measure it before choosing your size.<\/p>\n<h3>Why do the full-colour and kraft Medium and Large dimensions differ?<\/h3>\n<p>The two ranges are produced on different board stock and presses, and the size specifications were set independently for each. The Small is the same in both. The Medium and Large are genuinely different. This is not a tolerance variation: the kraft Medium will always be 300 x 230 x 115mm and the full-colour Medium will always be 310 x 240 x 110mm. Check the correct column in the comparison table before you order.<\/p>\n<h3>How does cubic weight affect my shipping costs?<\/h3>\n<p>Most Australian carriers price parcels by cubic weight above a defined threshold, calculated from the assembled external dimensions. A box that is significantly larger than your product needs can push your parcel from one weight band to the next, adding a freight surcharge to every shipment. Matching your box size to your packed product dimensions is the most direct way to keep carrier costs predictable and avoid repeating that surcharge at scale.<\/p>\n<h3>Can I order a custom mailer box size?<\/h3>\n<p>Yes. Custom sizes are available on request for both the full-colour and kraft ranges. Start with your packed product dimensions plus 15 to 25mm of clearance per side, and supply those as the minimum internal size you need when you request a quote. Custom sizes are priced per job based on dimensions, print method, and quantity.<\/p>\n<h3>Are the dimensions listed on the product page internal or external?<\/h3>\n<p>The dimensions listed on both product pages, and throughout this article, are internal dimensions: the usable space inside the assembled box. External dimensions are slightly larger because of the board thickness. Use the assembled external dimensions for carrier cubic weight calculations, not the internal figures from the product page.<\/p>\n<p>&#8212;<\/p>\n<p>Once you have your packed product dimensions, the size decision usually takes a few minutes. Run the measurement, add your clearance, and match it against the table above. Both product pages carry a live price calculator, so you can pick a size and a quantity to see the per-box price update in real time. <a href=\"https:\/\/printshop.paperlust.co\/products\/custom-full-colour-mailer-boxes\">Full-colour mailer boxes<\/a> are available from 10 units; the kraft range starts at 500.<\/p>\n<p><script type=\"application\/ld+json\">{\"@context\": \"https:\/\/schema.org\", \"@type\": \"FAQPage\", \"mainEntity\": [{\"question\": \"What are the standard mailer box sizes in Australia?\", \"answer\": \"There is no single national standard; each supplier sets their own range. Our full-colour and kraft mailer boxes each come in three sizes. The Small (265 x 200 x 90mm) is the same in both ranges. The Medium and Large differ: full-colour Medium is 310 x 240 x 110mm, kraft Medium is 300 x 230 x 115mm; full-colour Large is 425 x 295 x 110mm, kraft Large is 400 x 270 x 90mm. All are internal dimensions. Custom sizes are available on request.\"}, {\"question\": \"What size mailer box do I need for a T-shirt?\", \"answer\": \"A folded adult tee typically packs to around 230 to 250mm x 160 to 180mm x 20 to 30mm, depending on how tightly it is folded. Adding 15 to 25mm clearance per side puts you comfortably inside the Small (265 x 200 x 90mm). If you are sending two tees or adding a tissue layer that builds height, pack the actual bundle and measure it before choosing your size.\"}, {\"question\": \"Why do the full-colour and kraft Medium and Large dimensions differ?\", \"answer\": \"The two ranges are produced on different board stock and presses, and the size specifications were set independently for each. The Small is the same in both. The Medium and Large are genuinely different. This is not a tolerance variation: the kraft Medium will always be 300 x 230 x 115mm and the full-colour Medium will always be 310 x 240 x 110mm. Check the correct column in the comparison table before you order.\"}, {\"question\": \"How does cubic weight affect my shipping costs?\", \"answer\": \"Most Australian carriers price parcels by cubic weight above a defined threshold, calculated from the assembled external dimensions. A box that is significantly larger than your product needs can push your parcel from one weight band to the next, adding a freight surcharge to every shipment. Matching your box size to your packed product dimensions is the most direct way to keep carrier costs predictable and avoid repeating that surcharge at scale.\"}, {\"question\": \"Can I order a custom mailer box size?\", \"answer\": \"Yes. Custom sizes are available on request for both the full-colour and kraft ranges. Start with your packed product dimensions plus 15 to 25mm of clearance per side, and supply those as the minimum internal size you need when you request a quote. Custom sizes are priced per job based on dimensions, print method, and quantity.\"}, {\"question\": \"Are the dimensions listed on the product page internal or external?\", \"answer\": \"The dimensions listed on both product pages, and throughout this article, are internal dimensions: the usable space inside the assembled box. External dimensions are slightly larger because of the board thickness. 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