How to Build a Flat Panel TV Box for Shipping

Written by sylvia cini
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How to Build a Flat Panel TV Box for Shipping
Custom boxing allows you to fit additional padding or decrease box dimensions. (cardboard box image by MAXFX from

Flat screen TVs are easier to ship than their Direct View counterparts, as they are lighter and less bulky. However, their thinness and flat panels make them especially fragile for shipping. If you have not saved your original packaging, it is important to build a replacement flat panel TV box for shipping that will prevent scratches, crushing and movement during shipping. You can purchase cardboard sheets for box construction from retail stores such as Staples or Ace Hardware. Supermarkets and other large stores often have used cardboard for free.

Skill level:

Things you need

  • Cardboard
  • Measuring tape
  • Duct tape
  • Box cutter
  • Foam forms
  • Damage indicators

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  1. 1

    Measure the height, width and depth of the television at the widest areas. Include foam forms in the calculation if shipping with original packaging. Or add a 4-inch border to all sides as room for padding.

  2. 2

    Secure padding to the television. Tape foam forms together to create a protective coating. Finish with five to seven layers of shrink wrap.

  3. 3

    Purchase cardboard pads or buy a large box that you can dismantle. Be sure that you have enough for the full box dimensions. For example, a television that is 20 inches high, 10 inches long and 2 inches wide with padding included, requires 616 square inches of cardboard.

  4. 4

    Cut cardboard to size by scoring with a box cutter. Make a single flat sheet that is as long as twice the TV's height and width. This sheet should be as wide as the TV with space for the width at either end.

  5. 5

    Rest flat panel on cardboard so that the screen lines up with the cardboard panel. If you do not have foam forms, continue to shape the box without the TV.

  6. 6

    Score and fold the cardboard sheet to wrap the TV. Fold cardboard at corners and secure all joints with tape.

  7. 7

    Repeat with a second layer of cardboard, if desired. Be sure to use the dimensions of the cardboard-wrapped unit.

  8. 8

    Encase package with shrink wrap or packing tape.

  9. 9

    Secure damage indicators and fragile labels to the unit per shipping-service guidelines.

Tips and warnings

  • Check your local electronics store or shipping supplier for foam forms and TV boxes before making your own.
  • Do not use materials that have been crushed or show damage.

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