What Lengths Do Hair Extension Boxes Need to Fit?
Hair extensions sell in two inch steps from 8 inches up to 30 inches and 18 to 22 inches is where most volume sits. Length is always quoted pulled straight so a curly bundle measures shorter once it relaxes. Buyers add two inches for wavy hair and three to four inches for curly or coily.
That measuring rule matters for packaging because the box has to fit the hair stretched rather than the hair as it looks in the photograph.
Should the Bundle Lie Flat or Fold Inside the Box?
This one decision sets your whole size range and suppliers across the trade disagree about it. Some size the box to hold the bundle coiled so a 22 inch bundle travels in a box around 12 inches long. Others size it to hold the hair close to full length, which puts a 16 inch bundle in a box over 16 inches long.
Neither approach is wrong for every brand and the trade runs both. A folded bundle ships cheaper because the box around it is smaller. A flat bundle presents better on opening and avoids a crease across the weft.
We build to whichever you choose but the choice has to come before the dieline is cut. Changing it afterward means a new die rather than a simple edit.
Which Board Should Hair Extension Packaging Use?
| Format | Material | Best for |
|---|---|---|
| Folding carton with window | 350 to 400 GSM, 0.42 to 0.55 mm | Retail shelves and single bundles |
| Rigid two piece box | 1.5 to 2 mm grayboard, wrapped | Luxury lines and multi bundle sets |
| Kraft mailer | E flute corrugated | Ecommerce orders shipping direct |
| Sleeve over a tray | 300 to 350 GSM sleeve | Brands changing artwork often |
A window lets the buyer see texture and color without opening the pack. We patch windows with clear film so the cut opening stays rigid.
Can Hair Extension Boxes Hang on a Retail Peg?
The fixture to ask for is a euro slot rather than a plain punched hole. The standard slot cuts 32 mm wide by 9 mm high with a 6.5 mm bar. It hangs on retail pegboard running quarter inch holes on one inch centers in both directions.
Rigid boxes take a ribbon handle instead because a rigid wall will not hang cleanly from a punched slot. Both fixtures get decided at dieline stage rather than added once the box is built.
How Does a Multi Bundle Pack Differ From a Single Bundle Carton?
A single bundle carton holds one weft and it is sized from that one length. A three bundle pack has to hold three wefts side by side without letting them shift into each other. That is a different structure rather than the same carton scaled up.
Rigid boxes carry multi bundle sets better than folding cartons because the wall stays square under the extra weight. A wig box differs again since a wig sits on a cap and keeps its shape in three dimensions. That cap needs depth and a molded support that a flat weft box never carries.
| Pack | Usual structure | Board | What holds the hair |
|---|---|---|---|
| Single bundle | Tuck end carton with a window | 350 to 400 GSM folding carton | Printed inner sleeve or a ribbon tie |
| Two or three bundles | Drawer box or book style with a magnet | 1.5 to 2 mm grayboard | Die cut cradle with one well per bundle |
| Wig on a cap | Deep two piece rigid box | 2.5 to 3 mm grayboard | Molded insert under the cap crown |
Each line above is its own size and design and each one carries its own 100 box minimum.
Which Finish Holds Up on a Dark Hair Extension Box?
Most hair packaging prints dark because black and deep brown sit closest to the product itself. A dark matte carton shows every handling mark as a shiny line and those scuff marks appear long before the box reaches a salon shelf. We run an anti scuff matte film over deep colors for that exact reason.
Metallic detail is the other request we get constantly on this product. Foil stamping holds a crisp edge on both folding carton and wrapped rigid board.
Minimum Order, Lead Time, and Samples
- The minimum order is 100 boxes per size, so a four length range starts at 400 units
- Folding cartons run 8 to 10 business days after you approve the dieline
- Rigid and wrapped boxes run 10 to 12 business days because they are built rather than folded
- 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 the lengths you carry, your quantity and whether the bundle lies flat. We will come back to you with a price and a dieline to check.
The Customized Boxes