Size to the fold, not the garment
Fold the piece the way it will ship, add tissue, and measure the stack. Apparel mailers are 2 to 3 inches deep for a reason: a deeper box lets the garment slide and adds volume the carrier charges for. A tee usually fits 12 by 9 by 2 inches and a hoodie 13 by 10 by 3. Our carrier rate sizing guide explains how outside dimensions drive the shipping price.
Box or soft mailer
A box protects shape, gives you an inside print and a moment on opening. A soft mailer is lighter and cheaper to ship and suits basics and replacements. Many shops use both: a printed mailer for first orders and gifts, a poly or compostable mailer for repeat orders. If returns are part of the model, read our guide to packaging for returns before you pick a closure.
Finishes and inside print
Inside print is where apparel packaging earns its keep: a pattern or a message under the lid costs less than a rigid box and photographs well. Matte aqueous protects a printed mailer in transit. Keep tissue to one or two colors so it reads as a pattern, not a print job.
Labeling notes
Fiber content and care instructions belong on the garment label, not the box. The FTC rules are the Textile Fiber Products Identification Act rules (16 CFR part 303) and the Care Labeling Rule (16 CFR part 423), which requires a permanent care label attached to the garment.
This is packaging guidance, not legal advice.