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Author:Kangdi 03-09-2026
Pain Patch Sizes & Dimensions: Complete 2026 Size Chart (cm × cm)
Pain patches come in 12 standard sizes and unlimited custom shapes. The right size depends on the body area you're treating, the wear time, and the active ingredient release profile. This complete 2026 size chart shows every standard dimension, the body area each size targets, the typical active ingredient dosage, and the OEM MOQ impact. Built on kangdi medical's 17 years of OEM manufacturing data across USA, EU, GCC, LATAM, and Southeast Asia markets.
Reading time: 8 minutes. Includes 4 size charts + 1 body-area mapping.
Quick navigation
- 12 standard pain patch sizes
- Body area → size mapping
- Size vs wear time
- Size vs active ingredient dose
- Size impact on OEM MOQ
- Custom sizes & shapes
- Side-by-side size comparison
- FAQ
12 standard pain patch sizes
The 12 standard pain patch sizes cover 95% of all B2B orders. Each size has a specific body-area target and active ingredient dose range. Custom sizes account for the other 5%.
| Size # | Dimensions (cm × cm) | Area (cm²) | Common name | Primary use |
|---|---|---|---|---|
| S1 | 5 × 7 | 35 | Mini | Fingers, small joints, trigger points |
| S2 | 7 × 10 | 70 | Small rectangle | Wrists, elbows, ankles, small muscles |
| S3 | 8 × 12 | 96 | Medium rectangle | Neck, shoulders, calves, forearms |
| S4 | 10 × 14 | 140 | Standard rectangle | Lower back, upper back, thighs, knees |
| S5 | 10 × 18 | 180 | Long rectangle | Spine, full back, calf muscles |
| S6 | 10 × 25 | 250 | Extra-long | Spine (full length), large muscles |
| S7 | 12 × 18 | 216 | Wide rectangle | Shoulders (full), upper back, large joints |
| S8 | 12 × 25 | 300 | Wide + long | Lower back + hip, large body areas |
| S9 | 15 × 20 | 300 | Large square | Chest, abdomen (menstrual), large areas |
| S10 | 7 × 7 (round) | 38 | Round small | Trigger points, acupuncture points |
| S11 | 10 × 10 (round) | 79 | Round medium | Joint pain, circular muscle areas |
| S12 | 5 × 12 oval | 47 | Oval small | Neck sides, finger joints |
Size popularity (2025 kangdi data)
- S4 (10×14): 38% of orders — the "default" pain patch size
- S2 (7×10): 22% — small but very versatile
- S3 (8×12): 14% — popular in EU and USA markets
- S5 (10×18): 8% — common for back/spine applications
- Other 8 sizes: 18% combined
If you're a first-time OEM buyer, start with S4 (10×14 cm). It's the most universal and the cheapest per piece (due to production volume).
Body area → size mapping
Different body areas need different patch sizes. Below is a body-area guide based on 200+ kangdi buyer projects.
| Body area | Recommended size | Why |
|---|---|---|
| Neck (front/sides) | S3 (8×12) or S2 (7×10) | Neck is narrow; patch needs to fit without restricting movement |
| Shoulders (top) | S4 (10×14) or S7 (12×18) | Deltoid muscle area; needs full coverage for capsaicin warming |
| Upper back | S4 (10×14) or S7 (12×18) | Trapezius coverage; one or two patches depending on pain area |
| Lower back | S4 (10×14), S5 (10×18), or S8 (12×25) | Spinal muscles are long; larger sizes cover more area |
| Spine (full length) | S6 (10×25) | Covers from upper to lower back in one patch |
| Chest (menstrual/cramps) | S9 (15×20) | Large abdominal coverage; warming effect |
| Abdomen (general) | S9 (15×20) | Wide area; covers stomach muscles |
| Hip / glutes | S4 (10×14) or S7 (12×18) | Hip socket is medium-sized; multiple for full coverage |
| Thighs | S4 (10×14) or S5 (10×18) | Long muscles; larger sizes cover more |
| Calves | S3 (8×12) or S5 (10×18) | Calf muscles are long; one patch per calf |
| Knees (front) | S2 (7×10) or S11 round (10×10) | Knee cap is round; circular patches conform better |
| Knees (back) | S2 (7×10) or S3 (8×12) | Popliteal area behind knee; smaller sizes fit |
| Elbows | S1 (5×7) or S2 (7×10) | Elbow is small; mini size fits |
| Wrists | S1 (5×7) | Wrist is narrow; mini patches only |
| Hands / fingers | S1 (5×7) | Fingers and knuckles; very small patches |
| Ankles | S1 (5×7) or S2 (7×10) | Ankle is small; mini patches |
| Feet (sole) | S2 (7×10) or S3 (8×12) | Sole is wide; medium size |
| Trigger points (anywhere) | S1 (5×7) or S10 round (7×7) | Trigger points are 1-2 cm; small patches concentrate dose |
Size vs wear time
Patch size affects wear time in 3 ways.
1. Edge lift (larger patches lift more easily)
Larger patches have more edge surface area, which is more likely to catch on clothing and lift. For body areas with high friction (lower back, knees, shoulders), smaller patches stay on better.
2. Sweat accumulation
Larger patches trap more sweat underneath, which can reduce adhesion over time. In hot/humid climates (GCC, Southeast Asia), smaller patches are preferred.
3. Active ingredient reservoir
Larger patches contain more active ingredient. With the same release rate (mg/hour), larger patches wear longer. A 10×14 cm patch typically delivers 8-12 hours wear; a 5×7 cm patch delivers 4-6 hours wear.
| Size | Typical wear time (hydrogel) | Typical wear time (non-hydrogel) |
|---|---|---|
| S1 (5×7) | 3-4h | 4-6h |
| S2 (7×10) | 4-6h | 6-8h |
| S3 (8×12) | 5-7h | 7-10h |
| S4 (10×14) | 6-8h | 8-12h |
| S5 (10×18) | 6-8h | 10-14h |
| S6 (10×25) | 8-10h | 12-18h |
| S7 (12×18) | 6-8h | 10-14h |
| S8 (12×25) | 8-10h | 12-18h |
| S9 (15×20) | 8-10h | 12-16h |
Size vs active ingredient dose
The active ingredient dose is typically proportional to patch area. But the concentration (% or mg/cm²) stays constant. Here's the dose breakdown for the 4 most popular formulas.
| Size | Capsaicin 0.05% dose | Menthol 5% dose | Lidocaine 4% dose | Methyl salicylate 20% dose |
|---|---|---|---|---|
| S1 (35 cm²) | 2 mg | 175 mg | 140 mg | 700 mg |
| S2 (70 cm²) | 4 mg | 350 mg | 280 mg | 1,400 mg |
| S3 (96 cm²) | 5 mg | 480 mg | 384 mg | 1,920 mg |
| S4 (140 cm²) | 7 mg | 700 mg | 560 mg | 2,800 mg |
| S5 (180 cm²) | 9 mg | 900 mg | 720 mg | 3,600 mg |
| S9 (300 cm²) | 15 mg | 1,500 mg | 1,200 mg | 6,000 mg |
Note: actual dose varies ±10% depending on matrix formulation. kangdi tests each batch via HPLC and provides COA.
Size impact on OEM MOQ
Standard sizes have lower MOQ because factories already have die-cut tooling. Custom sizes require new tooling, which increases MOQ or adds one-time fees.
| Size type | Typical MOQ (custom branding) | Tooling fee | Lead time impact |
|---|---|---|---|
| Standard size (S1-S12) | 5,000 PCS | $0 (existing tooling) | None (15-25 days) |
| Custom size (standard tooling, different dimensions) | 10,000 PCS | $500-1,500 (one-time) | +7 days (tooling fabrication) |
| Custom shape (heart, oval, kidney, etc.) | 20,000 PCS | $1,500-3,000 (one-time) | +14 days (die-cut design + fabrication) |
| Stock size + custom printing | 2,000-5,000 PCS | $300-400/color | None (15-25 days) |
If your target size is not in the S1-S12 list, ask the factory if they have "near-standard" tooling (e.g., 8×13 cm is very close to S3 tooling and may not require new tooling). Small adjustments are usually free.
Custom sizes & shapes
Custom sizes and shapes are possible but require specific conditions.
Custom sizes (different dimensions, standard shapes)
- Most factories accept custom dimensions at 10,000+ PCS MOQ
- Tooling cost: $500-1,500 one-time
- Lead time: +7 days
- Best for: brands with specific positioning ("small for women," "large for athletes")
Custom shapes (heart, oval, kidney, anatomical)
- Custom shape requires die-cut tool design: $300-500 one-time
- Tooling fabrication: $1,200-2,500
- Total tooling: $1,500-3,000
- Lead time: +14 days
- Best for: novelty gift products, kids' products, gender-specific products
Anatomically shaped patches (spine, knee, shoulder)
- Most complex tooling: $2,500-5,000
- Lead time: +21 days
- Requires ergonomic validation (does it actually conform to body?)
- Best for: premium positioning, sports medicine, doctor-only products
Side-by-side size comparison
Visual size reference (approximate, not to scale):
| Size # | Dimensions | Visual (relative to 5cm square) | Relative cost per piece |
|---|---|---|---|
| S1 | 5×7 cm | ▓░░░░░░ (mini) | 0.7x baseline |
| S2 | 7×10 cm | ▓▓▓░░░░░ (small) | 0.85x baseline |
| S3 | 8×12 cm | ▓▓▓▓░░░░ (medium) | 0.95x baseline |
| S4 | 10×14 cm | ▓▓▓▓▓▓░░ (standard, baseline) | 1.0x baseline |
| S5 | 10×18 cm | ▓▓▓▓▓▓▓▓ (long) | 1.3x baseline |
| S6 | 10×25 cm | ▓▓▓▓▓▓▓▓▓▓ (extra-long) | 1.7x baseline |
| S7 | 12×18 cm | ▓▓▓▓▓▓▓▓░ (wide) | 1.3x baseline |
| S8 | 12×25 cm | ▓▓▓▓▓▓▓▓▓▓░ (wide+long) | 1.8x baseline |
| S9 | 15×20 cm | ▓▓▓▓▓▓▓▓▓▓░ (large) | 1.8x baseline |
Baseline = S4 (10×14 cm) cost per piece. Larger sizes cost more per piece due to more raw material and slower production speed.
FAQ
1. What's the most popular pain patch size?
10×14 cm (S4). About 38% of all pain patch orders globally use this size. It's the "default" because it fits most adult body areas.
2. Can I get a non-standard size at standard MOQ?
No. Non-standard sizes (anything outside S1-S12) require new tooling, which means MOQ 10,000+ PCS or one-time tooling fee $500-1,500.
3. Is a bigger patch always better?
No. Bigger patches cost more per piece, may stay on less well (edge lift), and over-dose the active ingredient for small body areas. Match size to body area.
4. What's the smallest patch size you can make?
3×5 cm is the practical minimum. Below that, production speed drops dramatically (alignment issues, wastage). kangdi's smallest standard size is S1 at 5×7 cm.
5. What's the largest patch size?
Practical maximum is 15×25 cm. Beyond that, the patch is unwieldy and difficult to apply. For larger body areas, recommend 2 patches instead of 1 oversized patch.
6. Can I mix sizes in one container order?
Yes. Most OEM factories accept mixed-SKU orders at 2,000+ PCS per SKU. kangdi's standard practice: 5,000 PCS minimum per SKU, unlimited SKUs per order.
7. Do different sizes need different artwork design?
Yes. Larger sizes have more space for branding, smaller sizes need minimal text. Each SKU needs its own artwork adaptation. kangdi includes artwork adaptation per SKU in the design fee.
8. Are round patches better for joints?
Yes. Round patches (S10, S11) conform better to joint surfaces (knees, elbows, knuckles) without corners that lift. For joint pain, recommend round or oval shapes.
9. What size do doctors prescribe most?
Doctor-recommended lidocaine patches (Rx) typically come in 10×14 cm or 10×18 cm. For OTC retail, the same S4 standard is most common.
10. How do I choose size for my target market?
USA/EU: prefer larger sizes (S4-S9, body-conscious market). GCC: medium sizes (S3-S4, modest coverage). Southeast Asia: smaller sizes (S1-S3, hot climate = smaller patches). LATAM: standard sizes (S4). kangdi provides market-specific recommendations based on 200+ buyer projects.
Next steps: request a size sample pack
Before placing your first bulk order, request a "size sample pack" — 10 patches each of S2, S3, S4, and S5 in your target formula. Test with 5-10 target customers to validate size preference. kangdi provides free size sample packs with 7-day delivery.
→ Request kangdi's size sample pack (4 sizes, 10 pcs each)
Test S2 (7×10), S3 (8×12), S4 (10×14), S5 (10×18) with your target customers → validate optimal size before placing bulk order.
About kangdi medical
kangdi medical is a 17-year pain patch OEM/ODM manufacturer based in Shenzhen, China. All 12 standard sizes in-stock tooling, no MOQ surcharge. Custom sizes accepted at 10,000+ PCS MOQ. ISO 13485 + CE MDR + FDA registered + GMP certified. 200+ brand buyers across USA, EU, GCC, LATAM, and Southeast Asia.
Related guides: 7 Types of Pain Patches | How Pain Patches Work | Hydrogel vs Non-Hydrogel | OEM Sample Process