Box Compatibility Guide
Box Compatibility Guide
Egg Armor™ products are shipped to you flat and ready to assemble. This guide explains which outer box options work with each kit configuration so you can choose the right setup for your shipping operation.
The Egg Armor Strongbox
The Egg Armor Strongbox is your primary outer shipping container. It ships to you flat and erects to the height you need using built-in score lines — one box covers all kit configurations.
Score-to Heights:
4" — Quail Single-Stack Kit (standard build)
5.5" — Chicken Single-Stack Kit & Quail Double-Stack Kit
8" — Chicken Double-Stack Kit & Quail Triple-Stack Kit
The Egg Armor Strongbox is compatible with all kit configurations and can be shipped via USPS, UPS, FedEx, or any carrier of your choice.
USPS Medium Flat Rate Box (FRM) Compatibility
The USPS Medium Flat Rate box has a fixed internal height of 5.5". You can use free USPS-supplied FRM boxes with the following Egg Armor configurations:
Direct FRM-Compatible Kits (no modifications needed):
| Kit Configuration | Total Height | USPS Medium FRM |
|---|---|---|
| Chicken Single-Stack | 5.5" | ✅ Fits directly |
| Quail Double-Stack | 5.5" | ✅ Fits directly |
Quail Single-Stack in a USPS FRM (with pad additions):
The standard Quail Single-Stack kit is 4" tall. You can fill the extra 1.5" of a USPS FRM box by adding Shielding Pads. Approved options to reach 5.5":
Standard build (2x 1.25" pads + 1 Core) + 2x 0.75" Shielding Pads = 5.5" ✅
Standard build (2x 1.25" pads + 1 Core) + 1x 1.5" Shielding Pad = 5.5" ✅
Alternate build: 1 Quail Core + 4x 1.0" Shielding Pads = 5.5" ✅
Additional pads are available individually in our Shielding Pads collection.
Kits requiring the Egg Armor Strongbox only:
| Kit Configuration | Total Height | Box Required |
|---|---|---|
| Quail Single-Stack (standard 4" build) | 4" | Egg Armor Strongbox scored to 4" |
| Chicken Double-Stack | 8" | Egg Armor Strongbox scored to 8" |
| Quail Triple-Stack | 8" | Egg Armor Strongbox scored to 8" |
USPS FRM boxes have a fixed height and cannot accommodate 4" or 8" configurations without modification.
One Footprint. Multiple Configurations.
Every Egg Armor™ component — Nest Cores, Shielding Pads, and the Egg Armor Strongbox — is built around the same 11 × 8.5" FRM platform footprint. This means:
One Strongbox SKU covers all five kit heights
Your foam system drops directly into USPS FRM boxes for compatible kits
No guesswork on sizing — everything is engineered to fit
Fewer box SKUs to stock and manage
How to Assemble Your Egg Armor System
When your Egg Armor order arrives:
Strongboxes ship flat — erect to your required scored height before packing
Assemble your foam system per the approved build for your kit
Pack your eggs and ship via your carrier of choice
For approved build configurations and layer-by-layer assembly details, see the Shipper Size Guide.
Why Box Strength Matters
The Egg Armor™ system is engineered as a complete unit. Your outer box is a critical layer of the armor stack — it resists compression, prevents flex during carrier stacking, and works with your foam to absorb impact. Weak or oversized boxes reduce system performance and are not recommended.
Questions?
Not sure which configuration is right for your operation? Contact us and we'll help you select the right build for your egg type, volume, and shipping method.
One footprint. Multiple configurations. Built for real-world shipping.