Due to the box being constructed out of corrugated cardboard, the edges are not at right angles. This means tolerance must be included in the sleeve dimensions. To give myself a proper idea of how much tolerance I should give I used a long piece of fashion card, wrapped it around the box and marked where the folds should be.
Another important decision I made was to construct the sleeve out of 2 pieces. This is because thicker card in size A0 is extremely hard to source and also extremely annoying to transport.
For the prototype I used 10 sheet card which was perfect for what I wanted as it provided strength and kept its structure after being removed from the box.
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