What Size Should a Custom Eyelash Box Be?
Work outward from the tray in three steps and the rest follows. Add side clearance of 1 to 2.5 mm per side so the tray drops in without forcing. Add top clearance of 2 to 5 mm above the tray and take the higher figure when the lash carries a tall curl. Then add board thickness on each face to reach the outside dimension.
A common single pair tray measures 118 by 58 by 12 mm in length and width and height. That tray needs an internal box of roughly 121 by 61 by 16 mm before any board thickness is added on the outside.
| Box style | Typical outside size |
|---|---|
| Tuck end folding carton | 110 to 125 by 55 to 70 by 18 to 25 mm |
| Drawer or matchbox style | 115 to 130 by 60 to 75 by 20 to 30 mm |
| Book style flap with magnet | 120 to 150 by 70 to 90 by 20 to 35 mm |
Why Does Top Clearance Matter More Than Length?
Because the curl is the part of the lash that actually gets damaged. The lash band is flat and survives pressure without complaint. The curl apex stands well above the tray and takes any load first. A box built tight to the tray height presses on that apex through every stage of handling.
A flattened lash cannot be fixed once the customer opens the box. That is why we treat top clearance as a specification on the dieline rather than as a rounding decision at the end.
Which Board and Tolerance Should You Specify?
| Specification | What we run |
|---|---|
| Folding carton board | 0.3 to 0.6 mm, printed and laminated |
| Rigid board | 1 to 2 mm for magnetic and book style boxes |
| Folding carton tolerance | plus or minus 0.5 to 1 mm |
| Rigid box tolerance | plus or minus 1 to 2 mm |
| Insert | Thermoformed PET tray, paperboard cradle, or a die cut foam bed |
| Artwork | Vector PDF or AI on our dieline, 3 mm bleed, Pantone identified |
Rigid boxes hold a looser tolerance than folding cartons so a magnetic lash box needs more clearance than a tuck end carton of the same tray.
What Do the FDA Rules Mean for Eyelash Packaging?
FDA treats false eyelashes and eyelash extensions and their adhesives as cosmetics. That means your carton carries the full cosmetic labeling set: the statement of identity, the net contents, the ingredient list and your name and place of business.
Two colorant rules matter here and both are easy to miss. Several color additives cleared for cosmetics in general are not cleared for use anywhere in the eye area. Eyelash and eyebrow dyes containing coal tar colors are subject to an FDA import alert. Permanent lash tints have caused serious eye injuries including blindness. Anything you print on the box has to match a product that follows those rules.
Minimum Order, Lead Time, and Samples
- The minimum order is 100 boxes per size, so a three style range starts at 300 boxes
- Folding cartons run 8 to 10 business days after you approve the dieline
- Rigid and magnetic boxes run 10 to 12 business days after dieline approval
- A plain sample takes 3 to 5 business days and a printed sample takes 7 to 10
- Price breaks land at 500 and 1,000 units on the same artwork
Request a Quote
Send us your tray dimensions and your run quantity and tell us whether the lash carries a tall curl. We will build the dieline with the right clearances and quote folding carton and magnetic rigid on the same size.
The Customized Boxes