BoxDiegen
· Mailer Box (Roll End)
BoxDiegen
· Mailer Box (Roll End)
Mailer Box Box is a very strong and durable box type thanks to its double side walls. Usually used as a mailer box. The double-wall tuck top box has one opening to the top, with two closing flaps that fold into the bottom of the box with a friction lock.
The mailer box is the strong, self-locking carton behind most e-commerce and subscription deliveries. This generator draws the roll end front tuck dieline, FEFCO 0427 style, in any size you enter, and exports it free as PDF and SVG.
A mailer box is a one-piece shipping carton whose base and lid are cut from a single sheet. The end walls and side walls fold up from the base, and the dust flaps wrap around the corners so the tabs on their edges drop into slots in the base and lock the frame together. The lid then folds over the top, its side flaps sliding down the walls, and the front tuck flap locks in with two rounded ears, so the closed box needs no tape or glue to stay shut, although most shippers add a strip of tape for posting.
This construction is listed in the FEFCO catalogue as style 0427, the roll end front tuck mailer. The double walls resist crushing far better than a single wall carton, and the flat, clean faces print beautifully, which is why this style became the standard unboxing box for online brands, subscription kits and gift shipping.
Mailer boxes are sized by their inside length, width and height. These popular sizes cover most online orders.
| Size (W × D × H) | Typical use |
|---|---|
| 152 × 102 × 51 mm (6 × 4 × 2 in) | Small electronics and accessories |
| 203 × 152 × 76 mm (8 × 6 × 3 in) | Cosmetics and skincare kits |
| 229 × 152 × 76 mm (9 × 6 × 3 in) | Books, apparel and small orders |
| 254 × 203 × 102 mm (10 × 8 × 4 in) | Subscription and gift boxes |
| 305 × 229 × 102 mm (12 × 9 × 4 in) | Shoes and larger orders |
Most mailer boxes are made from E flute or B flute corrugated board. E flute gives a smoother print surface and a slimmer box, while B flute adds cushioning and strength for heavier orders. Paperboard can work for very small, light mailers, but corrugated board is the safer choice for anything sent by courier.
In the file, red is the cut line, green dashed is a fold and blue dotted is a perforation. Print and fold a test box at 100 percent scale, pack your real product with its padding, and check the lid closes without bulging. A box that is slightly too tall wastes postage, and one that is too tight will strain the tuck lock.
Is the mailer box dieline really free?
Yes. The generator is free, needs no signup, and you can create and download as many mailer dielines as you like in PDF or SVG.
What does FEFCO 0427 mean?
FEFCO is the European federation of corrugated board makers, and its catalogue numbers describe standard box constructions. Style 0427 is the roll end front tuck mailer with double side walls, which is the style this generator produces.
Should I design to inside or outside dimensions?
Shipping boxes are normally specified by inside dimensions, because the product has to fit the space. Turn on the Inside size toggle, enter the space you need, and the generator adds the board thickness to the outside for you.
Which board is best for a mailer box?
E flute corrugated board suits most e-commerce mailers and prints smoothly. Choose B flute when the contents are heavy or fragile and you want more cushioning. Match the thickness field to the board you select.
Does a mailer box need tape or glue?
The box locks together on its own — the dust-flap tabs drop into slots in the base and the tuck flap’s ears lock the lid — so no glue is used in the structure. For posting, most brands still add one strip of tape or a sticker seal for security.
Can I print my branding on the mailer box?
Yes. Download the SVG to place your artwork on each panel in vector software, or send the PDF to your printer as the cutting guide. Keep text and logos a few millimetres away from folds and cut edges.