A LITTLE ROOM TO CLOSE
Get the lid fit right.
The lid needs room to slide over the base. The right amount depends on your paper and how you fold it.
What does “clearance per side” mean?
The generator adds the clearance twice to each base dimension. For an 80 × 60 mm base and 0.75 mm clearance per side, the lid’s panel is 81.5 × 61.5 mm. Lid wall height is a separate setting.
Fold-line size is not inside size
Length and width describe the distance between fold lines. Folded walls and glue tabs take up space. The tool does not automatically compensate for material thickness, so measure your object, allow extra space and test the real box.
If the lid is too tight
- Measure the PDF’s 50 mm line on both sheets. Fix print scaling before changing the design.
- Check that the folds follow the dashed lines and that the walls are square. Glue tabs should sit inside the adjacent walls.
- Increase clearance by a small amount, such as 0.25 mm per side, and reprint the lid. Keep the base dimensions unchanged so you can compare the result.
If the lid is too loose
Reduce clearance a little and try another lid. A 0.25 mm change per side changes the panel’s total length and width by 0.5 mm. Avoid changing several settings at once; record the paper and setting that worked.
What clearance should I start with?
The default is 0.75 mm per side, a starting point for experimentation. It is not a measured guarantee for any paper weight. Use cardstock your printer supports and make one sample before a batch. These templates have not yet been physically assembled in our testing.