Get 10% Off On Your First Order
Get 10% Off On Your First OrderFree Design Support on Every Custom OrderLow MOQ from 100Get 10% Off On Your First OrderFree Design Support on Every Custom OrderLow MOQ from 100Get 10% Off On Your First OrderFree Design Support on Every Custom OrderLow MOQ from 100Get 10% Off On Your First OrderFree Design Support on Every Custom OrderLow MOQ from 100
HomeCustom Mailer BoxesTuck Top Mailer Boxes

Tuck Top Mailer Boxes.

The simplest mailer in the family — fewer die cuts, faster to close, lower cost per box.

🏷 Key Specs
📦 500 min. order 15–20 business days lead time📐 Any size
✨ Finishes
Matte LaminationGloss LaminationKraft Natural
▤ Materials
E-Flute CorrugatedB-Flute CorrugatedKraft LinerWhite Coated Liner
☑ Features
Self-locking flapReinforced structureCustom sizesFree design help
❋ Trusted By 500+ Brands
NOVAAureliusORBITpixel.MUSEFormaLUMENkineticNOVAAureliusORBITpixel.MUSEFormaLUMENkinetic
★ GET A QUOTE24hr response

Your custom box, quoted.

⊙ No spam · 24hr response · No obligation

01
§ 01
500+
Brands Served
02
§ 02
15–20 business days
Day Standard Lead
03
§ 03
Free
Design Support
04
§ 04
Any Size
Size & Dimensions
05
§ 05
USA Wide
Free Delivery
The Atelier Book

The full specification book.

Six chapters. Six colours. Click a tab to turn the page.

Description
Overview

Tuck Top Mailer Boxes

The simplest mailer in the family — fewer die cuts, faster to close, lower cost per box.

A corrugated tray whose lid folds over and tucks into the front wall, with no side locking tabs. For light goods travelling in protected networks it is entirely adequate.

500
Min. order
15–20 business days
Lead time
Any size
Dimensions
Tuck Top Mailer Boxes
Matte Lamination · Gloss Lamination · Kraft Natural
Crafted to specification

Every detail. Intentional.

Fewest cuts in the family

A simpler die means less waste on the sheet.

Closes faster than a lock

Seconds saved per box add up on a hand-pack line.

Best for light, non-fragile goods

Apparel, soft goods and books travel well in it.

Honest about its closure

Less resistance to levering than a fully locking mailer.

E-flute as standard

Steps up to B-flute when contents get heavier.

Flat-shipped and stackable

Blanks store in a fraction of erected volume.

brand
No. 04 — Construction detail
Technical Specs

Built like architecture.

Each Tuck Top Mailer Boxes is an engineered object — measured, dieline-cut, and hand-wrapped to spec. Below: the standard build sheet.

Position
Simplest and cheapest mailer
Fewer die cuts
Trade-Off
Closure security for cost
The honest limit
When Fine
Light goods, protected networks
Consolidated shipments
When Not
Valuable or heavy contents
Step up to locking
Tape Irony
Taping it loses the advantage
Worth noting
Speed Advantage
Closes faster than locking mailers
Hand-pack lines
Best For
Apparel, soft goods, books
Light and not fragile
The Maths
One lost parcel erases many savings
Assess honestly

✦ Need a custom spec? Talk to our atelier — every detail is negotiable.

The Library

Every surface, hand-selected.

What this product is built from, and the surfaces it takes. Below the build sheet, the full swatch library — every option applies across our range, and a physical swatch set is available on request.

Material
E-Flute Corrugated
The standard weight.
Standard
Kraft Grades
Natural, direct-printable.
Economy
Litho-Laminated Options
Where print ambition rises.
Premium
Recycled Fluting
High recycled content.
Sustainable
B-Flute Step-Up
When contents get heavier.
Alternative
Finish
Flexo Kraft Print
The economy branding route.
Standard
Interior Print
The opening surface.
Unboxing
Right-Sized Dies
Freight economics.
Economics
Adequate Tuck Depth
Holds without fighting to close.
Functional
Tape-Free Design
The format's original virtue.
Practical
01 · Base Stock

Material

The board and paper your box is built from.

STOCK
Corrugated
Lightweight fluted strength
MT · E-FLUTE
ECO
FSC Recycled
100% post-consumer waste
MT · ECO
FINISH
corrugated board
FINISH
Honeycomb Board
02 · Surface

Finishes

How the outer surface looks, feels, and catches light.

FINISH
Matte Black
Light-absorbing, no glare
PT · MATTE
FINISH
Soft-Touch
Velvet to the fingertip
PT · SOFT
FINISH
Gold Foil
Hot-stamped brilliance
PT · 871 C
FINISH
Spot UV
Selective high-shine
PT · GLOSS
FINISH
Emboss
Raised, tactile, dimensional
PT · RELIEF
FINISH
Kraft Natural
Eco, uncoated, honest
PT · KRAFT
FINISH
Matte Lamination
FINISH
Gloss Lamination
FINISH
Soft Touch Lamination
FINISH
Gold Foil
FINISH
Silver Foil
FINISH
Spot UV
FINISH
Holographic Foil
FINISH
Embossing
FINISH
Debossing
FINISH
Anti Scratch Matte
FINISH
Aqueous Coating
FINISH
Full UV Coating
FINISH
Raised Spot UV
FINISH
Drip Off UV
FINISH
Pearl Coating
FINISH
Textured Varnish
FINISH
Sand Touch Coating
FINISH
Rose Gold Foil
FINISH
Rainbow Foil
FINISH
Copper Foil
FINISH
Foil Embossing
FINISH
Blind Embossing
FINISH
Multi Level Embossing
FINISH
Sculpted Embossing
FINISH
Die Cut Detailing
03 · Extras

Add-ons

Closures, linings, and hardware that complete the build.

FINISH
PE Foam Insert
FINISH
Molded Pulp Insert
FINISH
Dividers and Partitions
FINISH
Corrugated Insert
FINISH
Tear Strip
FINISH
Reusable Adhesive Closure
FINISH
Printed Tissue Paper
FINISH
Thank You Card
FINISH
Product Information Card
FINISH
Sticker Seal
FINISH
QR Code Card
FINISH
Corner Protectors
E-Flute CorrugatedB-Flute CorrugatedKraft LinerWhite Coated LinerMatte LaminationGloss LaminationKraft Natural

✦ Mix and match across all three — we'll build your exact combination.

What We Make

The full kit of capabilities.

Self-Locking Assembly
No glue or tape required — ships flat, assembles in seconds.
Tear Strip
Pre-perforated tear strip for clean, tool-free opening — standard on corrugated mailers.
Full Interior Print
Print inside the box lid or base — extend brand storytelling inward.
CMYK Exterior Print
Photo-quality print on all exterior panels.
Matte or Gloss Lamination
Protective laminate layer on outer surface.
Custom Die-Cut Interior
Die-cut insert platforms hold product securely in transit.
Double-Wall Option
Double-wall corrugated for heavy or fragile items.
Perforated Opening
Easy-peel opening strip for better unboxing experience.
Water-Resistant Coating
Repels minor moisture and surface scuffs during shipping.
Kraft Natural Finish
Uncoated kraft exterior — eco-aesthetic, fully recyclable.
Self-Lock AssemblyCMYK PrintingInterior PrintTear StripCustom Die-Cut
Measure Twice

Sizing & dieline.

Every Tuck Top Mailer Boxes is cut to a dieline built around your product — not pulled off a shelf. Send us the length, width and height of the item (or the item itself) and we return a measured dieline, free, before you commit to anything.

Size Range
Any size — built to your product
Custom dieline
Stock Dimensions
Common: 8 × 6 × 3 in · 10 × 8 × 4 in — tuck-top mailers
L × W × H
Dieline File
Free with every quote
AI / PDF / DXF
Artwork Setup
Free structural design
Included
Tolerance
±1.5 mm on finished size
Industry standard
How to measure
01
Measure the product

Length, width and height of the item itself, at its widest points — not the box you happen to use today.

02
Add clearance

Allow 2–4 mm on each axis for a snug fit, and more if you are adding foam, a pillow insert or tissue.

03
Give us the order

We quote as Length × Width × Height. Tell us whether you are working in millimetres or inches and we match it.

✦ Not sure of your size? Send us the product — we measure it and build the dieline.

What It Costs

Pricing & minimums.

Tuck Top Mailer Boxes is priced per specification rather than from a fixed list — the same box in two different finishes can land at very different numbers. Below is what actually moves the price, so you can shape the spec before you request a quote.

Minimum Order
500 units
Lower MOQ on request
Maximum Run
100,000 units
Larger volumes quoted
Standard Lead Time
15–20 business days
After artwork approval
Rush Lead Time
10–12 days
Surcharge applies
Pricing Model
Quote-based, per specification
USD
Design & Dieline
Free — included in every quote
No setup fee
Sampling
Physical sample before bulk
Credited on order
What moves the price
Quantity

The single biggest lever. Unit cost falls sharply as volume rises, because setup and tooling spread across more pieces.

Material and thickness

Board weight and stock choice change both the raw material cost and the shipping weight of the finished run.

Finishing

Foil, spot UV, embossing and soft-touch each add a pass on press. One or two lift the box; five compound the cost.

Print coverage

Full-bleed print inside and out costs more than a one-sided design on natural stock.

Inserts and hardware

Foam, moulded pulp, velvet pillows, magnets and ribbon are priced per piece on top of the box itself.

Timeline

Standard production is the base rate. Rush moves you up the production queue and carries a surcharge.

✦ Quotes returned within 24 hours — no obligation, no account required.

Client Voices

What brands say.

The best packaging partner we've ever worked with. Every box feels like an event.
Sarah M.
Head of Brand · Luxe Cosmetics
Our unboxing experience went from forgettable to remarkable. The magnetic close is chef's kiss.
James L.
Founder · Apex Spirits
Fast turnaround, flawless quality, and the design support is genuinely exceptional.
Priya K.
Creative Director · Kalon Jewelry
— Frequently Asked Questions —

Questions, answered.

Everything you need to know about Tuck Top Mailer Boxes.

Tuck Top Mailer Boxes from PackTist can be fully customized: dimensions to your exact product specifications, full-color custom print inside and out, choice of board weight and material, matte or gloss lamination, foil stamping, embossing, spot UV, and specialty finishes. Tell us your product dimensions and brand requirements — we'll recommend the right specification for your application and budget.
PackTist's MOQ is 500 units for most folding carton and flexible packaging formats, and 100 units for rigid box construction. Contact our team for specific MOQ information on your packaging format.
Standard production is 15–20 business days after artwork approval. Rush production at 10–12 days is available when timelines require it. Contact PackTist for current production schedule availability for your specific order.
— Related Products —

Other products you might love.

View All
— The Atelier —

Ready to start your Tuck Top Mailer Boxes project?

Get a free quote in 24 hours. No commitment required. Our atelier is here to help.

✦ No spam · 24hr response · No obligation

Where We're Trusted
Google
★★★★★
Trustpilot
R
REVIEWS.io
Our Logistics Partners
Secure Payment Options
SSL Secured