Corrugated Mailer Boxes.

RETT stands for roll end tuck top, the one-piece die-cut style most e-commerce mailers are built on. The side panels roll over and lock into the base, and the lid hinges from the back and tucks in at the front.

There is no tape and no separate lid, and the customer opens it by hand. Variations on the same blank add ear locks, tear strips or a perforated opening.

When the blank is folded, the side panels roll over on themselves, so each wall ends up two layers thick. That doubling gives the box its stiffness without paying for a heavier board.

It also explains why a well-made mailer keeps its shape on a doorstep when a single-wall carton in the same flute would crush. The dust flaps tuck inside the doubled walls and add a little more rigidity at the corners.

E-flute, at about 1.5mm, suits most e-commerce mailers, and B-flute at about 3mm is the step up for heavier or more fragile contents. E-flute prints more cleanly and folds tighter. B-flute gives more crush protection at the cost of a slightly bulkier box, and a double-wall build is available for the heaviest loads.

Both use fluting with a high recycled content as standard. Tell us the packed weight and we'll recommend one.

Litho-laminated board is the choice for photographic, full-colour exteriors, while flexo printed straight onto kraft suits one or two colour logos. Litho gives a sharper image and a smoother surface for matte or gloss lamination. Flexo costs less and leaves the natural board showing.

Interior print is inexpensive to add on either version, and it means the lid opens onto your brand instead of plain board.

The front tuck is the weak point on this style, and a poorly fitted one can spring loose when the parcel is squeezed or dropped. We test the tuck fit on samples so the lid stays closed without being a struggle to open.

If your goods are heavy or the route is rough, an ear-lock version holds the lid along its sides as well as the front. A water-resistant coating is worth adding for parcels that sit on porches.

Carriers bill by dimensional weight, so every extra inch of box is paid for on every parcel. We measure mailers by inside length, width and depth and cut the die close to the product.

Common sizes include 8 × 6 × 2, 10 × 8 × 4 and 12 × 9 × 4 in. A custom die sized to your item cuts both the void fill and the billed weight, which matters more the more orders you ship.

Corrugated mailers have a minimum of 500 boxes. That covers a first branded run for most online shops, and the die we cut for it stays on file for reorders.

Artwork setup and dieline help are free, so the minimum run doesn't carry a design fee on top of the boxes themselves.

Once your proof is approved, the run takes 7 to 10 business days, and a rush order can be done in 5 to 7. For a new size we'd make a sample first, in 5 to 7 business days, so you can pack it and check the tuck holds.

We knock the sample fee off the production invoice, and the flat-packed boxes ship anywhere in the USA.