6 × 4 × 4 in box: dimensions, dim weight and strength
A 6 × 4 × 4 in box holds 96 in³ (0.06 ft³) inside. Made in C flute its outside is about 6.31 × 4.31 × 4.47 in, which dimensional weight bills USPS at actual weight (under its threshold) and FedEx at 1 lb.
Key numbers
| Inside (L × W × H) | 6 × 4 × 4 in |
|---|---|
| Inside volume | 96 in³ · 0.056 ft³ · 1.6 L |
| Inside, metric | 152 × 102 × 102 mm |
| Perimeter 2(L + W) | 20 in |
| Length + girth, C flute OD | 23.9 in |
Outside dimensions by flute
| Board | Caliper, in | Outside, in | Outside volume, ft³ |
|---|---|---|---|
| E flute | 0.063 | 6.13 × 4.13 × 4.19 | 0.061 |
| B flute | 0.125 | 6.25 × 4.25 × 4.38 | 0.067 |
| C flute | 0.156 | 6.31 × 4.31 × 4.47 | 0.07 |
| EB double wall | 0.188 | 6.38 × 4.38 × 4.56 | 0.074 |
| BC double wall | 0.281 | 6.56 × 4.56 × 4.84 | 0.084 |
OD ≈ ID + 2 calipers on length and width, + 3 on depth. An estimate: your box maker sets the scores. Convert other sizes.
Dimensional weight
| Carrier | Divisor | Measured, in (C) | DW, C flute | DW, BC double wall |
|---|---|---|---|---|
| USPS | 139 | 7 × 5 × 5 | n/a | n/a |
| FedEx | 139 | 6 × 4 × 4 | 1 lb | 2 lb |
DW = ⌈L × W × H ÷ divisor⌉ on outside dimensions, after each carrier's own rounding. USPS applies it only above 1,728 in³ (n/a means it bills actual weight). The carrier bills the greater of actual and dimensional weight. Divisors checked on carrier pages 2026-10-27; try your own weight.
Estimated compression strength
| Board | BCT, lbf | After 30 days storage |
|---|---|---|
| 32 ECT B flute | 297 | 178 |
| 32 ECT C flute | 332 | 199 |
| 44 ECT C flute | 457 | 274 |
| 48 ECT C flute | 498 | 299 |
| 48 ECT BC double wall | 668 | 401 |
| 61 ECT BC double wall | 849 | 510 |
| 71 ECT BC double wall | 989 | 593 |
Simplified McKee: BCT ≈ 5.87 × ECT × √(caliper × 20). The 30-day column applies Packgent's default 40% storage loss, an assumption. Estimates only; test with ASTM D642.
Pallet pattern on 48 × 40
| Board | Per layer | Layers | Boxes per pallet | Load height, in | Cube used |
|---|---|---|---|---|---|
| C flute | 66 | 12 | 792 | 59.1 | 92% |
| BC double wall | 62 | 11 | 682 | 58.8 | 95% |
Column stacked, no overhang, on a 48 × 40 in deck 5.5 in tall, loaded to 60 in overall. Those three are assumptions you can change in the pallet calculator. Pattern: 4.3125″ along the 48″ side.
Blank size in C flute
With one caliper allowance per score. Multiply board area by your board's combined weight (lb/MSF ÷ 1,000) for box weight, or use the box weight calculator.
Sources
- USPS Domestic Mail Manual 223 (Priority Mail prices and eligibility), section 1.4
- FedEx: What is dimensional weight?
- Flute calipers: Foster (1997), Wiley Encyclopedia of Packaging Technology
- McKee, Gander & Wachuta (1963), Paperboard Packaging 48(8)
Last reviewed . See all sources and how Packgent computes.
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