What size lingerie box do I need for bras, panties and bridal sets?

What are the standard lingerie box sizes by garment type?

Intimate apparel spans everything from a single pair of sheer mesh briefs weighing under an ounce to a three-piece bridal silk robe, slip and garter trousseau set. Trying to pack that entire range in one universal box either crushes your molded contour bras or leaves tiny lace briefs rattling inside an oversized carton. Most intimate apparel brands standardize around three core box footprints: a slim retail carton for panties and wireless bralettes, a mid-depth drawer or two-piece box for A-C cup sets, and a deeper box for full-bust D-G cups, bodysuits and robes. Use the inside-dimension chart below as your starting point when quoting custom printed lingerie cartons.

How do I measure molded underwire bras for a box without creasing the cups?

When shoppers open a boutique bra box, the two molded cups should greet them round, smooth and symmetrical. In warehouse fulfillment, packers sometimes fold a bra in half at the center gore and invert the left foam cup inside the right foam cup so the bra fits into a narrow 6 × 6 inch mailer. While that works for unlined sheer lace, inverting a heat-molded contour foam cup forces the foam dome backward against its curve, leaving a sharp vertical dent down the center of the inverted cup that shows through fitted t-shirts. To measure an underwire bra for an open-lay box, place the bra face-up on a flat table in its natural wearer position. Fold the left and right elastic wing bands and shoulder straps neatly behind the underwire channels so nothing extends past the outer wire tips. Measure the horizontal span from the outer tip of the left underwire to the outer tip of the right underwire (Length), the vertical height from the bottom wire cradle to the top of the cup peak or strap apex (Width), and the vertical dome loft from the table surface to the highest point of the foam cup crown (Height). Add 0.5 inch to Length and Width so tissue paper wraps around the cups without pinching, and add 0.25 inch to Height so the lid never presses the foam flat.

1. Length (L): outer tip of left underwire to outer tip of right underwire + 0.5 in for tissue wrap.
2. Width (W): bottom wire cradle to top cup peak (plus space below if matching briefs sit below the bra).
3. Height (H): table surface to the highest point of the molded cup dome + 0.25 in top clearance.
4. Push-up padding allowance: graduated gel or foam push-up pads add 0.25 to 0.5 in of extra dome height.
5. Matching panty placement: either tuck the folded panty underneath the center gore or add 1.5 in to box Width.

How do I size compact cartons for wireless bralettes, briefs and hosiery?

Unlined lace bralettes, microfiber briefs, thongs, garter belts and sheer stockings have no rigid underwire or foam dome, so they fold into crisp, flat rectangles. For boutique pegboards and department store hosiery walls, smaller cartons save valuable shelf frontage and keep the garment from sliding to the bottom of the package when hung vertically. To keep a folded pair of briefs or a wireless bralette square inside a vertical straight tuck end box, wrap the garment around a smooth white or kraft cardstock folding board cut 1/8 inch smaller than the inside length and width of the carton. A 5.25 × 3.75 inch card insert inside a 5.5 × 4.0 × 1.0 inch carton holds a pair of silk briefs completely flat behind a front acetate window so the lace pattern stays centered.

What size box fits boned corsets, bodysuits and bridal silk robes?

Structured corsets, bustiers and longline bridal bras contain vertical steel or spiral plastic boning channels sewn into the torso panels. You can never fold a boned panel horizontally across the waist, because bending steel or plastic boning warps the channel and pops the stitching. Measure the full vertical length of the longest front busk or side bone, and make that measurement your inside box Length (typically 12.0 to 13.5 inches). For bias-cut silk slips, satin kimono robes and three-piece honeymoon sets, fabric weight causes the folded garment to slide if the box is too deep. A 14.0 × 10.5 × 3.5 inch magnetic closure rigid box or collapsible rigid box gives a silk robe enough surface area to fold in thirds with only two gentle horizontal folds, minimizing creases across high-sheen charmeuse.

1. Boned corsets and bustiers: measure the longest vertical bone channel and never fold across the boning.
2. Lace and mesh bodysuits: fold the snap gusset up behind the torso and lay molded cups open at the top.
3. Silk slips and camisoles: fold around an acid-free tissue sheet or smooth card board so slippery silk stays put.
4. Multi-piece bridal sets: place the robe on the bottom layer, tissue barrier in the middle, and open bra on top.

How many box sizes does a full-size-range bra brand actually need?

A typical intimate apparel brand carries 24 to 40 band-and-cup combinations, running from 30A to 42G. Ordering 30 different box sizes is unnecessary and splits your printing volume into tiny runs. Instead, group your entire size matrix into two or three shared carton sizes: Use a Small Flat box (7.0 × 5.5 × 1.5 in) for all wireless bralettes and panty sets, a Medium Cup box (9.5 × 6.5 × 2.5 in) for underwire bands 30 to 36 in A through C cups, and a Large/Full-Bust Cup box (11.0 × 7.5 × 3.25 in) for bands 38+ and all D through G cups. Both underwire boxes can start at our 1,000-unit folding carton minimum or 250-unit custom mailer box minimum, with a clean end-panel zone for your size barcode sticker so warehouse staff can scan every SKU on the shelf.

What are the most common lingerie box sizing mistakes?

Most intimate apparel returns and damaged-cup complaints trace back to five avoidable sizing mistakes

1. Inverting one molded foam bra cup inside the other to fit a small square box, creating a permanent vertical crease down the foam dome.
2. Measuring a 32B sample bra to set your only box size, then discovering that 36DD and 38G underwires are 2 inches wider and crush against the side walls.
3. Packing a lightweight pair of lace briefs inside a vertical hang-tab carton without an inner folding card, so the fabric slumps to the bottom.
4. Folding a boned bustier or corset across the waist to fit a short box, permanently bending the vertical boning channels.
5. Ordering outside box dimensions instead of inside dimensions on thick double-wall drawer boxes, losing 0.25 inch of interior width.

Find your size

Packaging for this

Custom Lingerie Boxes

Custom Apparel Boxes

Custom Swimwear Boxes

Custom Tray and Sleeve Boxes

Custom Tissue Paper

Custom Scarf Boxes

More guides