Custom Underwear Boxes

Folding and Sizing the Pack

The box size depends on how you fold the garments. Fold several in the way you plan to pack them, stack them, and measure length, width and height. Boxers and briefs usually fold into a neat rectangle around a card insert, which keeps the shape while the waistband shows through the window.

For multipacks, decide whether garments sit stacked or fanned so each colour shows. A fanned arrangement shows more variety but needs a wider box and a shaped insert. A stacked arrangement is compact but only shows the top garment, so the colours inside are often shown printed on a side panel.

Allow for the insert thickness and a little room so the pack slides in without crumpling the fabric. If you sell several sizes in the same box, size it for the largest and use the insert to take up the slack in smaller sizes.

Send us a folded sample if you can. Fabrics vary in bulk, and a pack of thick cotton trunks needs noticeably more depth than the same number of microfibre briefs. A physical sample lets us size the carton and insert precisely. p3 The guide to measuring soft products for a box covers folded garments.

What to Print on Underwear Packaging

Shoppers want the size, the style (boxer, trunk, brief, hipster), the fabric and the number of pieces, so make those clear on the front. A size chart on the side or back helps first-time buyers, and care instructions belong there too. A model photograph showing the fit is common on premium lines.

Use a sticker panel or a printed size grid so one box design can serve several sizes. A tick box or a size sticker is much cheaper than printing separate boxes for every size and colour.

Keep branding consistent across your range so customers can find your products on a busy shelf.

A small line about the fabric story, such as combed cotton, a knit with no side seams or a moisture-wicking blend, gives the shopper a reason to pay more than for a basic pack. Keep it short and specific rather than general claims about comfort. p3 Base layers and compression wear use the same panel plan on our gym and fitness boxes page.

Board, Finish and Feel

White folding boxboard gives crisp colour reproduction and suits most retail lines. Black board with foil or white ink gives a bold, premium look popular with men's underwear. Kraft board suits organic cotton and natural fibre brands. Rigid board is used for luxury gift boxes.

Matt and soft touch laminations give a premium feel and resist fingerprints, which matter for boxes that get picked up often. Gloss makes photography pop. Foil stamping on the logo and spot UV on a pattern add shelf appeal.

Think about the window film as well. A clear film keeps dust and fingers off the fabric while still showing it, which matters for pale colours that mark easily. An open window lets shoppers feel the fabric, which some brands want for a soft modal or bamboo blend, but it does expose the garment to handling.

Shelf life is long for underwear, so the box may sit in a stockroom or on a shelf for months. A laminated finish keeps it looking fresh, and a board stiff enough not to bow under stacked packs avoids the tired, curved look that cheaper cartons get.

Who Orders Underwear Boxes

Underwear and lingerie brands selling through stores, sportswear brands with base layers and compression wear, sock and hosiery companies, department store own labels and online brands that also sell wholesale all order these boxes. Many start with a window carton for their core multipack and add gift boxes for premium lines.

Corporate gift suppliers and subscription services also order underwear boxes, often with a personalised card inside.

Brands moving from online-only to wholesale often find that their first stockist asks for retail-ready packaging. A window carton with a barcode, clear sizing and a hang option is usually what buyers expect, and having it ready makes the conversation with a store much easier. p2 Online brands sending single pairs often use our printed poly mailers for the everyday orders.

Send a Folded Pack of Your Thickest Style

Underwear boxes are sized by bulk, and bulk is set by the fabric. Three pairs of thick cotton trunks folded round a card insert stand 20 mm taller than three microfibre briefs, so measure the pack you actually sell, folded and stacked as it will go in, and if you can, post one to us. Decide stacked or fanned at the same time, because a fanned pack needs a wider carton and a shaped insert.

Plan one artwork with a size grid or a sticker panel rather than a box per size, and send the size chart, fabric composition and care text for the back. The custom quote arrives by email within one working day, from £0.25 for a window carton, with the minimum set per job so a new label can start small.

The free proof shows the window position against the folded pack. Production takes 4 to 7 working days after approval and the flat cartons reach UK mainland addresses by free tracked delivery. Brands adding a lingerie line usually order our deeper boxes for bras and lingerie at the same time so the shelf reads as one range.