Double sleeving is the highest-protection option for valuable cards. Every dimension changes meaningfully when a card has both an inner perfect-fit sleeve and an outer sleeve. A deck box designed for single-sleeved cards that you then double-sleeve will either be too tight to close or will crush the sleeves when the lid goes on. This guide gives the specific numbers for double-sleeved card dimensions and how they translate to deck box interior tolerances.
Double-Sleeve Dimensions by Common Combination
| Inner sleeve | Outer sleeve | Width | Height | Per-card thickness | 60-card depth |
|---|---|---|---|---|---|
| KMC Perfect Fit | Dragon Shield Matte | 67.5mm | 93mm | 0.65mm | 39mm |
| KMC Perfect Fit | Ultra Pro Eclipse | 67mm | 92.5mm | 0.62mm | 37mm |
| Dragon Shield Perfect Fit | Dragon Shield Matte | 68mm | 93.5mm | 0.68mm | 41mm |
Box interior for double-sleeved 60-card deck (KMC + Dragon Shield): 69.5mm wide x 95mm tall x 42mm deep. That is 2-3mm wider and 1-2mm taller than a single-sleeve box for the same deck.
The Tolerance Problem with Double Sleeves
Double-sleeved cards have slightly rounded corners where the two sleeve layers stack. This corner profile means the cards don’t sit perfectly flush against the box walls. The recommended 1.5mm clearance per side for single sleeves increases to 2mm per side for double sleeves. Less than 2mm clearance and the cards catch on the box walls when removing.
Test this with a calibration slot before printing a full box: a 25mm deep U-channel at your target width, printed in 20 minutes. Slide your double-sleeved deck into it. Cards should move freely up and down with light resistance. If they bind, add 0.5mm to interior width and reprint the calibration slot.
For printing, eSUN Matte PLA is smooth enough that cards slide cleanly once the clearance is correct. Textured filaments or rough surfaces add friction that can cause card binding even at correct dimensions.
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