Mailer boxes — roll-end tuck top
Custom Mailer Boxes
A mailer box is a one-piece corrugated box that locks closed on itself: the side flaps roll under, the lid folds over and the front tab tucks in, with no tape or glue at packing. It is the box that reaches the customer by courier and is opened at home, which is why e-commerce, subscription and apparel brands print it inside and out.
- Family
- Mailer boxes
- Best for
- E-commerce, subscriptions, apparel, kits
- Minimum order
- 50 boxes
- Sizing
- Made to your dimensions
Construction
How it is built, and how it opens.
How it is built
The blank is a single sheet of corrugated board, die-cut and scored, with a floor, two side walls that fold up and roll over into double thickness, a back wall that continues into the lid, and a front wall with the tuck tab on the lid. There is no glue seam: the box is held together by the roll-end sides and the tucked lid. Dust flaps and locking tabs can be added for a tighter close, and a tear strip for a clean opening.
How it closes and opens
At packing the side walls are folded up and their flaps rolled under to lock, the product goes in, and the lid folds over with its front tab tucked behind the front wall. The double-thickness sides give the box its stiffness in a courier's hands. To open, the customer lifts the tab and the lid, and the first thing seen is the inside of the lid, which is the panel worth printing. Made to the product, the box has no void to fill.
Board and print
E-flute, at roughly 1.5 mm, is the default: a fine flute that folds crisply and takes sharp print. B-flute, at roughly 3 mm, is chosen for heavier contents or longer journeys. The liner is white for full-color print, kraft for a single-color brand mark, and either can be printed inside and out. Interior print is a second pass on press and is the change that turns a delivery into an unboxing. Coating, spot UV and foil stamping are available on the outer liner.
Packing, shipping and cost
Mailers ship flat and are erected at packing without tools or tape. On cost they sit between a folding carton and a rigid box: more board than a carton, far less labour than anything wrapped. A mailer sized to the contents is smaller and lighter to send than a stock carton padded out with void fill, and it travels on its own without an outer box, which is where much of the saving is found.
What it suits
Where a mailer box box earns its place.
E-commerce
Any product sent to a customer by courier, in a box that is the packaging rather than a container for it.
Subscription kits
A monthly box sized to the largest configuration, with a board insert that presents the items.
Apparel
Folded garments with printed tissue, in a mailer whose inside lid carries the brand.
Kits and sets
Several items in a die-cut corrugated insert that holds each in place through transit.
Retail cartons in transit
A printed mailer around a shelf carton, so the delivery and the shelf pack are both branded.
Finished work
Mailer boxes we have made.
Roll-end front-tuck mailer 
Roll-end front-tuck mailer · Interior print 
Roll-end front-tuck mailer · Single-color print 
Roll-end front-tuck mailer
- Internal dimensions (L × W × D), the contents and their combined weight. Every mailer is made to your dimensions.
- Flute: E-flute for most retail-weight products, B-flute for heavier contents or longer journeys; otherwise we recommend.
- Liner: white or kraft, and whether the print is outside only or inside and out.
- Closure extras: locking tabs, dust flaps, tear strip; finishes on the outer liner: matte or gloss coating, spot UV, foil stamping.
- Insert, tissue and any printed cards to be supplied with the box.
Or consider
When another style does the job better.
Collapsible Rigid
Choose it when the delivery should feel like a rigid gift box and still ship flat to the packing table.
Read the guideCorrugated Lid & Base
Choose it for heavier products such as footwear, where a separate lid and base suit the product better.
See the styleInsert & Divider
Add one when several items travel together or the product must not move in transit.
See the style
Start a quote
Three answers is all it takes to open a job.
Structure, board and finishing come next — with our team, on the full quote form.
No account needed. Artwork and reference images can be attached on the next step.
Mailer Box questions
Before you ask.
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat is a mailer box?
A one-piece corrugated box, usually a roll-end tuck top, whose sides roll under and lid tucks in so it closes without tape. It is made to the product and printed with your brand.
Does a mailer box need tape?
No. The roll-end sides and tucked lid lock on their own. Locking tabs or a tear strip can be added where tamper evidence is wanted.
Which flute should I choose?
E-flute for most retail-weight products and the sharpest print; B-flute for heavier items or longer journeys. Send the weight and the route and we recommend.
What is the minimum order for custom mailer boxes?
The minimum order for custom mailer boxes is 50 boxes, the same as every structure we make. Your quote shows the price at each quantity you ask for.
How long does production take?
Standard production is 10–12 working days from proof approval and payment. Ground shipping adds 3–5 working days, and delivery is free on every order.
Can I get a sample before the full run?
Standalone samples are chargeable, because making one box or a handful takes the same setup and production steps as a full run. On a qualifying bulk order, once the order is placed we produce a pre-production sample for your approval at no extra sample charge, and the remaining quantity runs after you approve it.
Start here
Send us your dimensions. We’ll send back a box.
Or talk to a packaging specialist: (209) 444-0744