We compute the mass function of bound states of asymmetric dark matter - nuggets - synthesized in the early Universe. We apply our results for the nugget density and binding energy computed from a nuclear model to obtain analytic estimates of the typical nugget size exiting synthesis. We numerically solve the Boltzmann equation for synthesis including two-to-two fusion reactions, estimating the impact of bottlenecks on the mass function exiting synthesis. These results provide the basis for studying the late Universe cosmology of nuggets in a future companion paper.