Tuck Box Template

How to use the tuck box template tool

1. Enter Inside length (L), the width of the front face. For a poker-size playing card, use 63 mm.
2. Enter Inside depth (W), the width of the side faces, which is the thickness of the contents. A poker-size deck is about 18 mm thick.
3. Enter Inside height (H), the height of the box. Use 88 mm for a poker-size card.
4. Choose a Tuck end style: reverse tuck end (RTE) or straight tuck end (STE).
5. Tick Dust flaps if the contents are small or loose.
6. Tick Thumb notch on the front panel if you want a notch to lift the lid.
7. Open More options and set the Glue flap width and the Material thickness for your board.
8. Read the result rows: Flat size (mm), Flat size (in), Fits one sheet? and Panel sizes. Check any warning shown above them.
9. Open How it was calculated to see each step worked out with your own numbers.

Each value has its own unit menu, so you can switch between millimeters, centimeters and inches. The template is drawn in millimeters and also reported in inches. Use Download SVG (true size) for printing and design software, or Download DXF (CAD / cutter) for CAD programs, plotters and cutting machines. For paper printing, choose Print / save as PDF and print at 100%, not “fit to page.” Copy link keeps all your inputs so the same template reopens, Copy result copies the result lines, and Reset restores the default values.

What is the difference between a reverse tuck and a straight tuck box?

A reverse tuck end (RTE) box has its top and bottom tuck flaps on opposite sides: in this tool the top lid hangs on the back panel and the bottom lid on the front panel. A straight tuck end (STE) box has both tuck flaps on the same side, so both lids hang on the back panel. The choice changes where the lids sit in the flat net, but not its size. The same inside size and thickness give the same flat width and height for RTE and STE, so choose the style that suits how the box should open. The names RTE and STE describe common carton styles; the drawing is the tool’s own geometry.

How is the flat size of a tuck box worked out?

The wall panels wrap around four folds, so each one is its inside size plus the material thickness, written as t. The flat width is the glue flap plus two front/back panels plus two side panels:

Flat width = glue flap + 2 × (L + t) + 2 × (W + t)

The flat height is the inside height plus the two closure panels, each with its tuck flap:

Flat height = H + 2 × (closure panel + tuck flap), where the closure panel is W + t and the tuck flap is the smaller of 0.8 × W and H ÷ 2

For example, a 60 × 40 × 100 mm box in 0.3 mm cardstock with a 12 mm glue flap gives 12 + 2 × 60.3 + 2 × 40.3 = 213.2 mm wide and 100 + 2 × (40.3 + 32) = 244.6 mm high. Because t is added at every fold, a thicker board makes a larger net. This is why the material thickness setting matters even when your inside measurements stay the same.

Is the calculator free, and is anything I type uploaded?

Yes, the tool is free and needs no sign-up. It runs entirely in your browser, and nothing you type is uploaded. Your measurements are used only to calculate the template on your screen.

Can I use the results in commercial work such as quotes and bids?

Yes. Templates and results may be used in commercial work, including boxes and bags that are sold and files sent to printers and die makers. No attribution is needed. A template is still a starting point, because board thickness, grain direction, the printer and the cutter all change the fit. Make a sample before a production run.

Sources

• Panel sizes, flaps and curves are plain geometry (no packaging standard is copied); FEFCO style codes are used only as names
• Paper sizes: A4 210 × 297 mm and A3 297 × 420 mm (ISO 216), US Letter 8.5 × 11 in and Tabloid 11 × 17 in (ANSI/ASME Y14.1)
• 1 in = 25.4 mm exactly (NIST SP 811)

Worked examples

Calculated by the tool above with these values.

Frequently asked questions

What inside size should I enter for a playing card tuck box template?

For a standard poker-size deck, enter 63 mm for inside length, 18 mm for inside depth and 88 mm for inside height. Playing cards measure about 63 × 88 mm, and a deck box needs a little clearance around the deck, so you may want to add a millimeter or two to each measurement.

What does “Fits one sheet?” mean, and what should I do if it says no?

It tells you whether the flat net fits on one US Letter or A4 sheet with a 1/4 in margin. If it does not fit, print the template tiled across sheets, print it on A3 or Tabloid, or send the SVG or DXF file to a plotter or cutter.

When should I turn on dust flaps?

Turn on dust flaps when the contents are small or loose. Without them, the corners of the box stay open.

Which material thickness should I enter?

Enter 0.2 mm for paper, 0.3 mm for cardstock and 0.5 to 1 mm for chipboard. From 1.5 mm up, the tool advises scoring every fold line, and over 3 mm it warns that thick board will not fold at a sharp fold line, so use a creasing rule and test a sample first. The thickness menu offers mm or in.

Related tools

• Box template generator: Use it when you need a template for a box shape beyond the tuck style covered here.
• Pizza box dieline: Use it when you are making a pizza box and need a dieline for that shape.
• Rectangle box template: Use it for a plain rectangular box with a lid or closure different from a tuck end.
• Gift box template: Use it when you want a template for a gift box rather than a small tuck box.
• Gable box template: Use it for a box with a gable-style top.
• Pillow box template: Use it for a pillow-shaped box with a curved or puffed look.
• Paper bag template: Use it when you need a flat pattern for a paper bag rather than a box.
• Card box template: use it for a tuck box sized to a deck of poker or bridge cards.
• All calculators: Use it to browse the other calculators on this site.