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Hi Andrew,
Good question! Here are some principles that I usually consider:
a) Avoid super “long” boxes (e.g. Power Grid) as they are likely to be much more expensive to ship than corresponding “square” boxes of the same weight (as any side that is disproportionately long triggers dimensional weight in many regions) AND they will get damaged so much easier.
b) Try to fit the game inside a Kallax shelf (13 x 13 x 13″) so that more gamers can easily store your game. If any of your dimensions are larger, your game may be more likely to be culled due to less places for them to store it.
c) Make your game box thicker as you increase in box size and weight. Any large game should have at least 2 mm thick boxes to reduce damages and I would even consider 2.5 mm thick when the weight exceed 10 lbs.
d) Consider paying for extra packaging at the factory to protect your games in transit. I personally like doing 1-2 layers of bubble wrap around the game within the cartons – this is the most economical option. But you can also explore foam, plastic / cardboard corner protectors, box within the carton, etc. Some factories are easier to work with on requests like this than others.
