Rule and assumptions
Average circumference = pi x average diameter. Split mode divides height into upper and lower zones. Clearances are starting points.
- Handle shape and brand model can change printable zones.
- A physical test wrap is recommended before production.
Use this tool for
- Estimating 40 oz tumbler wrap size for handled cups.
- Splitting a 40 oz template into top and bottom zones.
- Checking a handle-safe panel before printing.
- Avoiding one-piece wraps on strongly tapered 40 oz cups.
Worked example
Inputs
- Unit: inches
- Template mode: top and bottom split
- Top diameter: 3.90 in
- Bottom diameter: 3.10 in
- Body height: 8.90 in
Result
The calculated wrap width is about 11.00 in, with a split suggestion around 4.63 in for the top zone and 4.27 in for the bottom zone.
When to use this
Use this when a handled 40 oz cup cannot be treated as one simple rectangle.
What to check before pressing
Check handle clearance, taper difference, split alignment, and seam overlap with a paper test wrap.
Quick reference chart
| Use case | Starting point | Check before pressing |
|---|---|---|
| Split wrap | Top and bottom panels | Best for handled cups |
| One-piece | Only if handle allows | Risky for tapered bodies |
| Panel | Handle-safe smaller art | Use for centered graphics |
Common mistakes
- Ignoring the handle cutout.
- Using one-piece rectangles on a tapered handled cup.
- Not allowing overlap or bleed.