Why Is My Trade Show Case Suddenly “Oversize”? New Rules Can Double Your Shipping Cost
Short answer: since January 2026, FedEx and UPS bill any package over 17,280 cubic inches (10 cubic feet) or over 110 lb as Oversize or Large Package, even if it passes the old 130" length + girth test. To check a case, round each outside dimension up to the next whole inch and multiply length × width × height. Staying under the line saves roughly $215 to $300 per package at FedEx's 2026 list rates, and display cases usually ship to the show and back, so that's twice per event.
For years, the shipping rule of thumb for trade show cases was simple: keep length + girth under 130 inches and you'd stay clear of the big oversize charge. That rule still exists, but in January 2026 FedEx and UPS added a second test on top of it, one that catches many cases that used to slip through.
What changed in 2026
FedEx made the change effective January 12, 2026, and UPS followed on January 26, 2026. Both carriers now use the same size triggers, measured as length × width × height:
- Additional Handling: any package over 10,368 cubic inches (6 cubic feet), in addition to the existing length, girth and weight triggers. FedEx's 2026 list charge is roughly $29.50 to $40.75 per package.
- Oversize (FedEx) / Large Package (UPS): any package over 17,280 cubic inches (10 cubic feet) or over 110 lb, in addition to the existing 96" length and 130" length + girth triggers. FedEx's 2026 list charge is roughly $255 to $330 per package, depending on zone.
The old rules didn't go away. A package that triggers any one of them still pays. The new cubic test simply means a tall, deep case can no longer squeak under the oversize line just because its length + girth comes out to 128 or 129 inches.
How to measure your case
- Measure the outside of whatever the shipping label goes on: the case itself, or the carton if the case ships inside a box.
- Round each dimension up to the next whole inch. The carriers do this, so 26.75" counts as 27".
- Multiply length × width × height.
- Compare the result: under 10,368 in³ has no size surcharge, 10,368 to 17,280 in³ is Additional Handling, and over 17,280 in³ is Oversize.
A real example: four popular shipping cases
Here are four cases we ship every week: three vertical cases from our vertical display case collection for pop up and tube displays, plus the XD Flat Shipper Case 49x25 that our Twist counters and kiosks ship in. All four pass the old 130" length + girth test. Only one crosses the new 10 cubic foot line. Every measurement below is rounded up to the next whole inch, the same way FedEx and UPS measure.
| Case | Billed size | Cubic inches | Length + girth | 2026 result |
|---|---|---|---|---|
| XD Flat Shipper Case 49x25 | 51" × 28" × 11" | 15,708 | 129" | Additional Handling only |
| CA700 Case w/Black Fabric Wrap | 43" × 16" × 23" | 15,824 | 121" | Additional Handling only |
| Medium Shipping Case | 22" × 40" × 18" | 15,840 | 120" | Additional Handling only |
| OCX Shipping Case | 27" × 40" × 17" | 18,360 | 128" | Oversize |
Billed size: 51" × 28" × 11"
Cubic inches: 15,708
Length + girth: 129"
2026 result: Additional Handling only
Billed size: 43" × 16" × 23"
Cubic inches: 15,824
Length + girth: 121"
2026 result: Additional Handling only
Billed size: 22" × 40" × 18"
Cubic inches: 15,840
Length + girth: 120"
2026 result: Additional Handling only
Billed size: 27" × 40" × 17"
Cubic inches: 18,360
Length + girth: 128"
2026 result: Oversize
The OCX Shipping Case is a great case. It's roomy, rugged, and converts into a podium with an optional printed wrap. But at 26.75" × 39.5" × 17", it rounds up to 27" × 40" × 17", or 18,360 cubic inches. That's about 1,080 cubic inches over the line. Under the old rules it would have been fine at 128" length + girth. Under the 2026 rules, it's billed as Oversize every time it ships.
The XD Flat Shipper, CA700 and Medium Shipping Case all land in the Additional Handling zone, at least 1,440 cubic inches under the line. They still carry a surcharge, but it's a fraction of the oversize fee.
What it adds up to
At FedEx's 2026 list rates, the gap between an Additional Handling charge and an Oversize charge is roughly $215 to $300 per package, before fuel surcharges. Because a display case ships to the show and back, that's two charges per event. An exhibitor doing six shows a year could spend $2,500 or more just on the oversize charge, for a case that holds the same display as one a few inches smaller.
Your actual numbers depend on your carrier account, zone and service level, and negotiated rates can differ from list rates. The size triggers are the same for everyone, though.
Tips for avoiding oversize charges
- Size the case to the display, not the other way around. If your display fits in a case under 10 cubic feet, you've avoided the biggest surcharge before you ship anything.
- Check the shipping size, not the interior size. Wheels, handles, molded lids and outer cartons all count. Use the exterior or shipping dimensions listed on the product page.
- Watch the outer box. A case that ships inside a carton is measured by the carton. A few inches of packaging on each side can push a borderline case over the line.
- Keep it under 110 lb. Weight alone now triggers the Oversize charge, even if the case is small enough.
- Split heavy kits. Two Additional Handling cases often cost less to ship than one Oversize case.
Cases that stay under the oversize line
Swipe to see more →
XD Flat Shipper Case 49x25
The rotomolded flat case our Twist counters and kiosks ship in. 15,708 cubic inches as billed.
View the XD case
CA700 Case w/Black Fabric Wrap
A shipping case that converts to a counter with a fabric wrap. 15,824 cubic inches as billed.
View the CA700
Medium Shipping Case
A hard shipping case with wheels for pop up and tube displays. 15,840 cubic inches as billed.
View the caseSee all vertical display cases and trade show shipping cases, or read our shipping case buyer's guide.
Common questions
Is the oversize charge the same as dimensional weight?
No. Dimensional weight is a separate calculation: length × width × height divided by 139 at FedEx and on UPS daily rates. You're billed for whichever is greater, the actual weight or the dimensional weight. The Oversize or Large Package charge is added on top of that, and those packages are billed at a minimum of 90 lb.
Would freight be cheaper for a big case?
It can be. These surcharges apply to parcel service. LTL freight is priced by weight, freight class and distance, so several large cases on one pallet can cost less than shipping each one by FedEx or UPS. Freight is slower, and delivery usually needs a loading dock or a liftgate.
I already own a case that's over the line. What are my options?
You can keep using it and pay the charge, ship it by freight with the rest of your booth, or move the display into a smaller case. If you ship to several shows a year, compare a year of oversize charges with the price of a case under 10 cubic feet.
Need help choosing a case?
Tell us what display you're shipping and how often you travel, and we'll help you pick a case that protects your display without paying for extra cubic inches.
Surcharge thresholds and FedEx 2026 list amounts as reported by Supply Chain Dive. Carrier rates change; check your own FedEx or UPS account for current pricing.
