Shipping Case Guidelines: Size Limits, Carrier Rules & Dimensional Weight Explained
Shipping sensitive equipment requires more than just choosing a carrier—it requires understanding size limits, dimensional weight calculations, and how different shipping methods impact cost, protection, and transit reliability. This guide breaks down shipping case requirements across major carriers including USPS, UPS, FedEx, and freight providers, helping you choose the right case and shipping method for your application.
Shipping Carrier Size & Weight Limits for Protective Cases
United States Postal Service (USPS) Shipping Limits
The United States Postal Service (USPS) is commonly used for smaller shipping cases and APO/FPO military shipments. Maximum size and weight limits vary by destination, but in most cases:
- Maximum combined length + girth: 108 inches
- Maximum weight: 70 lbs
USPS is best suited for lightweight protective cases and smaller equipment shipments where cost efficiency is a priority.
Go to www.usps.com for specifics. Cases2Go uses USPS for shipments to APO addresses whenever possible.
United Parcel Service (UPS) Shipping Limits
The United Parcel Service (UPS) supports larger and heavier protective shipping cases, making it a common choice for commercial and industrial equipment transport.
- Maximum size: 160 inches, calculated as length + girth of package (length + 2x depth + 2x height)
- Maximum weight: 150 lbs per package
UPS also applies dimensional weight pricing, which can significantly impact shipping costs depending on case size.
UPS uses several other dimensional factors when computing ground rates, as well as dimensional weight rules, when computing air rates - please go to www.ups.com for specifics.
FedEx & Air Freight Forwarders
FedEx and other air freight carriers are ideal for time-sensitive or international shipments. While there are fewer strict size limitations compared to parcel carriers, shipments must still comply with aircraft capacity constraints (such as Boeing 747 cargo limits).
Air freight carriers calculate shipping costs based on:
- Actual weight
- Dimensional weight (whichever is greater)
Dimensional weight is calculated by multiplying the three outside dimensions of the package (or pallet) and then dividing by 194 (domestic shipments), or 166 (international shipments). If the dimensional weight exceeds the actual weight, it becomes the chargeable weight for the shipment.
Freight Shipping (LTL & Truck Carriers)
Truck carriers have very high weight limitations and size limitations of 102" wide x 102" high. Rates are computed based on the NMFC (National Motor Freight Classification) system.
How to Choose the Right Shipping Method for Your Case
Selecting the right shipping method depends on the size, weight, and sensitivity of your equipment, as well as how quickly it needs to arrive. Understanding how each carrier handles protective shipping cases helps ensure your equipment is delivered safely, efficiently, and within budget.
- USPS: Best for small, lightweight cases and APO/FPO shipments where size and weight are limited
- UPS / FedEx: Ideal for mid-size equipment and standard protective cases requiring reliable ground or air delivery
- Freight Carriers (LTL/FTL): Recommended for large, heavy, or fully integrated systems that exceed parcel limits or require palletized shipping
Shipping Case Design Considerations
The design of your shipping case plays a critical role in protecting equipment during transit—especially when handling, vibration, and environmental exposure are factors. Choosing the right case configuration can significantly reduce damage risk and improve operational efficiency.
- Custom foam inserts help secure equipment in place, preventing movement and minimizing the risk of impact damage during transit
- Integrated equipment solutions allow components to remain mounted and ready for deployment, reducing setup time upon arrival
- Rugged shipping case materials such as rotationally molded polyethylene or aluminum provide durability against repeated handling, stacking, and harsh shipping environments
By combining protective case engineering with thoughtful interior design, you can ensure your equipment arrives protected, organized, and ready for immediate use.
Not sure which shipping case or carrier is right for your application?
Talk to a Cases2Go specialist
Cases2Go provides custom-engineered shipping case solutions with foam interiors and full equipment integration—designed to meet carrier requirements and protect mission-critical equipment.