What Are the Dimensional Limits and MOQ Realities for Custom Pillow Boxes? Pillow boxes aren't infinitely scalable. Their structural integrity depends on a length-to-width ratio that remains within certain boundaries. Practical dimensional ranges: Minimum length: 80 mm – shorter than this, and the tuck flaps become too small to hold. Maximum length: 300 mm – beyond this, the curved panels lose their arch and the box collapses under its own weight. Diameter (width when assembled): Typically 30–100 mm. A wider pillow box (over 100 mm) needs thicker board (20+ pt) to maintain the rounded shape. Aspect ratio rule: Length should be at least 2.5× the assembled diameter. For example, a 60 mm diameter box needs at least 150 mm in length. Violating this ratio makes the box look like a squashed cylinder rather than a pillow. https://www.customshinepack.com/products/boxes/custom-pillow-box