- A roll end tuck front (RETF) corrugated mailer folds from one flat sheet with double side walls and front locking ears.
- Supports outside and inside printing plus card or foam inserts for a clean unboxing reveal.
- CubitPack makes custom mailer boxes from 250 units in 10–14 business days, with 4–5 day rush available.
- Free design help, no die or plate charges, free US shipping, and a digital proof and 3D mockup before payment.
Custom Mailer Boxes
Custom mailer boxes are one-piece corrugated roll end tuck front (RETF) boxes that fold together without glue, using double-thick rolled side walls and front locking ears to protect orders in the mail. They suit e-commerce orders, subscription kits, apparel, cosmetics, candles, and PR boxes. Minimum 250 boxes, made in 10–14 business days (rush in 4–5 days), with free design help and free shipping across all 50 states.
What are custom mailer boxes?
Custom mailer boxes are self-locking corrugated boxes built in the roll end tuck front (RETF) style, standardized internationally as FEFCO 0427. Die-cut from a single sheet of corrugated board, the box forms a sturdy base tray by rolling the left and right side walls 180 degrees over bottom extensions and clicking tabs into floor slots. That fold creates double-thick side walls and reinforced corners that resist parcel sorting pressure without needing glue during assembly. A flat lid hinges from the back wall, carries two side dust flaps that tuck inside the tray walls, and finishes with a front tuck flap whose rounded locking ears (often called cherry locks) slot into the double-layered front wall. Because the flat sheet prints cleanly on both faces before die-cutting, brands use mailer boxes to pair durable exterior shipping protection with full-color inside printing and fitted inserts. At CubitPack, custom mailer boxes start at 250 boxes, take 10–14 business days, and include a digital proof and 3D mockup before you pay.
How is a roll end tuck front mailer box built?
A single die-cut sheet of corrugated board folds into a double-walled tray and hinged lid with zero glue. Here is how each part of the flat dieline works. Whether your team calls them printed mailer boxes, corrugated mailer boxes, roll end tuck front mailer boxes, custom mailer boxes with logo, custom printed mailer boxes, mailer boxes with logo or branded mailer boxes, every sheet is cut to your exact inside dimensions.
- 1Base, back and hinged lid
Form the continuous central spine from the bottom floor up the back wall and across the top cover. - 2Rolled double side walls
Fold up and roll over 180 degrees to lock tabs into the floor, doubling the side-wall thickness. - 3Side dust flaps
Extend from the hinged lid and fold inside the rolled side walls to keep out dust and brace the top. - 4Front tuck flap
Hinges down from the front edge of the lid to cover the front wall cleanly. - 5Locking ears (cherry locks)
Rounded tabs at both ends of the front tuck flap that slot into the front wall to hold the lid shut.
Mailer box facts
- Closure
- Hinged lid, front tuck flap with locking ears
- Best for
- E-commerce, subscription kits, PR sets, apparel
- Inside print
- Yes, outside and inside printing
- Inserts
- Yes, card, EVA foam, or EPE foam
- Minimum
- 250 boxes
- Turnaround
- 10–14 business days, rush 4–5
- Materials
- White corrugated, kraft corrugated, recycled
- Arrives
- Flat or assembled
- Size range
- Any inside L × W × H to order
Mailer boxes vs shipping boxes vs subscription boxes
| Mailer | Shipping | Subscription | |
|---|---|---|---|
| Structure | Roll end tuck front (RETF) with double side walls | Regular slotted container (RSC) with four meeting flaps | Roll end tuck front mailer tuned for recurring kits |
| How it closes | Front tuck flap and locking ears (tamper seal optional) | Packing tape across top and bottom flap seams | Front tuck flap with locking ears and security seal |
| Unboxing presentation | Hinged lid opens like a chest to show inside print | Four flaps fold back for utilitarian bulk packing | Full inside-and-outside storytelling with inserts |
| Weight capacity | Light to medium-heavy retail and e-commerce kits | Heavy bulk cartons, master cases, and large goods | Curated multi-item sets up to medium parcel weight |
| Minimum order | 250 boxes | 250 boxes | |
| Often used for | Direct-to-consumer orders, apparel, beauty, gifts | Outer master cartons, heavy hardware, bulk freight | Monthly club boxes, onboarding kits, VIP drops |
Save this comparison
The styles on one sheet. Pin it, or share it with whoever packs your boxes.
Still deciding between styles?
Request a Quote →Is a custom mailer box right for my product?
- You ship direct to customers and want the box to arrive looking like a gift
- You want double corrugated side walls that assemble in seconds without glue
- You want inside lid printing or a custom card or foam insert
- Your order starts at 250 boxes or more
- You pack multiple items, apparel, jars, or kits that benefit from a wide top opening
- You are shipping heavy bulk master cases sealed with packing tape: shipping boxes
- You want a thick luxury keepsake box with hidden magnets: magnetic closure boxes
- You need a thin paperboard carton for a retail store shelf: straight tuck end boxes
- You want natural brown board with simple one-color or white ink: kraft mailer boxes
- You need a fitted cavity tray built specifically around multiple items: mailer boxes with inserts
What are custom mailer boxes used for?
Direct-to-consumer brands use roll end tuck front mailers for everything from monthly clubs to influencer kits. Explore each product page for sizing and ideas.
What are custom mailer boxes made of?
Mailer boxes use corrugated board with a fluted inner layer for crush protection. Pick white corrugated for vivid graphics or kraft corrugated for an earthy texture.
Which finishes work on a corrugated mailer box?
What can I add to a custom mailer box?
Mailer box specifications
| Spec | Options |
|---|---|
| Construction | One-piece roll end tuck front (RETF) corrugated mailer, rolled double side walls, hinged lid, side dust flaps, front locking ears |
| Board | White corrugated, kraft corrugated, recycled corrugated |
| Flute and thickness | Corrugated board, card (paperboard) or kraft board matched to parcel weight |
| Printing | Outside only or outside + inside; full color CMYK, Pantone, white ink on kraft |
| Lamination | No lamination, matte, gloss, soft-touch |
| Finishes | Foil stamping, embossing, debossing, spot UV |
| Add-ons | Card insert, EVA foam insert, EPE foam insert, tissue paper, custom shape |
| Size range | Any inside size to order; smallest and largest |
| Quantity | From 250 boxes; delivered within ±5% of the order |
| Proofs | Digital proof and 3D mockup before payment; printed sample optional |
| Turnaround | 10–14 business days; rush 4–5 days |
| How boxes ship | (flat or assembled) |
Ready to quote mailer boxes? Compare up to 3 quantities with a free 3D mockup.
Request a Quote →What goes on each panel of a mailer box?
- 1Top lid (outside)
Your primary canvas: center the brand logo or run an edge-to-edge pattern. - 2Front tuck flap
Carries a tagline, website URL, or alignment graphic where the lid tucks in. - 3Inside of the lid
The unboxing focal point: place a welcome headline, QR code, or brand story. - 4Inside tray floor and walls
Flood-coat in a brand color or print an all-over pattern under your insert. - 5Bottom exterior
Keep a flat uncreased zone clear for the shipping label and return address.
Mailer box design ideas
Example designs with made-up brands. Your box is made to your design.
What are the most common custom mailer box mistakes?
Most mailer issues happen when brands measure the outside of an old box or crowd artwork into the locking slots. Avoid these five pitfalls. For buyers ordering wholesale mailer boxes, bulk custom mailer boxes, personalized mailer boxes, custom size mailer boxes, mailer boxes with base, back and hinged lid, mailer boxes with rolled double side walls or mailer boxes with side dust flaps, watch out for these common sizing and artwork mistakes
- Quoting outside dimensions instead of inside dimensions. Rolled double side walls take up interior width, so always measure the usable inside space.
- Placing small text over the front locking ear slots. Keep logos and copy at least 0.25 inches clear of score lines and cherry-lock cutouts.
- Skipping an insert when shipping multiple glass jars. Use a card, EVA foam, or EPE foam insert so bottles cannot clink together.
- Forgetting space for the 4 by 6 inch shipping label. Plan where the carrier label and tamper-evident seal sit so they do not cover your main logo.
- Leaving too much empty headspace above the product. Match the inside height to your items and insert so the lid stays supported against parcel stacking.
Chat with a designer now
Share your logo, a sketch or an AI image. We'll rebuild every element cleanly onto your box dieline and send a 3D mockup, free.
Made your design with AI?
Generated a concept in Google Gemini, ChatGPT, Claude or Midjourney? Send us your AI image: we rebuild every element onto your box dieline and show you a 3D mockup before you pay, free.Custom vs stock mailer boxes: which is better?
| Stock (plain) boxes | Custom boxes from CubitPack | |
|---|---|---|
| Branding | Plain, or a label on the front | Your logo and colors, inside and out |
| Fit | Fixed sizes | Made to your exact size |
| Minimum | Any quantity | 250 boxes |
| Lead time | Ships right away | 10–14 business days, rush 4–5 |
| Design | None | Free design help, proof and 3D mockup |
Get custom mailer boxes made to your exact size, with a free 3D mockup before you pay.
Request a Quote →Are mailer boxes eco-friendly?
Kraft and recycled board
Choose kraft or recycled board for a lower-impact box.FSC paper available
FSC paper and ISO 9001 production are available on request.Food-safe on request
For food, we make it in a certified partner facility. Certificates and lab tests on request.How do I order custom mailer boxes?
Tell us what you need
Size, quantities or AI conceptCompare volume pricing
Dedicated account managerApprove your proof
Digital proof + 3D mockupMade and shipped
Free to all 50 statesHow much do custom mailer boxes cost?
The price depends on four things, and every custom quote is free.
Size
Bigger packaging uses more materialQuantity
The unit price drops as you order moreMaterial
The board, film or paper you chooseFinishes
Foil, windows and lamination add costYour first order is 10% off, and we beat written quotes from US competitors for the same specs.
10% off your first order.
Request a Quote →What do I need to send for a quote?
- The product and how many you need
- The inside size, or what goes in it
- A style, or ask us to suggest one
- Your logo or artwork (an AI image is fine)
- Pantone codes, if you have them
- Delivery ZIP code and the date you need it
Can I see a sample first?
Sample kit
Board and finish swatches, sample boxes, labels and bags. Credited to your first order.Digital proof + 3D mockup
See it before you payPrinted sample
Of your own designHow do the boxes ship?
- Free shipping to all 50 states
- Worldwide with DDP prices: duties and taxes included
- Blind and split shipping
- Damaged in transit? We reprint the damaged units free
Why brands choose CubitPack
Dedicated specialist
One account manager from quote to deliveryPantone guaranteed
Clearly off? We reprintReprint or refund
If we get it wrong, you chooseBBB accredited
A US business you can checkMailer box questions
What is a roll end tuck front (RETF) mailer box?
A one-piece corrugated box whose side walls roll over to form double-thick walls, while the hinged back lid closes with side dust flaps and a front tuck flap with locking ears. It folds together by hand without glue.
What is the difference between a mailer box and a shipping box?
A mailer box uses self-locking rolled walls and a hinged lid designed for branded unboxing and smaller parcels. A regular slotted shipping box (RSC) has four meeting flaps at the top and bottom that require packing tape and suits heavy bulk freight.
Do custom mailer boxes need tape to ship in the mail?
The locking ears hold the lid closed during assembly and handling, and many brands add a single strip of branded tape or a tamper-evident sticker across the front edge before handing the parcel to postal or courier networks.
How do I measure my product for a custom mailer box?
Measure the length (left to right), width (front to back), and height (bottom to top) of your product group or insert, then add a small clearance so items lift out easily. Always enter inside dimensions in the quote form.
Can you print on both the outside and inside of a mailer box?
Yes. You can print full-color CMYK or Pantone graphics on the outside, the inside, or both. Inside printing turns the underside of the lid and the tray walls into part of the unboxing reveal.
Can I add a custom insert to hold bottles or jars?
Yes. Mailer boxes pair with folded card inserts, EVA foam inserts, or EPE foam inserts cut to the exact profile of your jars, cans, dropper bottles, or electronics.
What is the minimum order for custom mailer boxes?
250 boxes for custom mailer boxes. Unit prices drop at higher quantities such as 500, 1,000, and 2,500, and trial orders are considered case by case if you ask your account manager in the quote form.
Can I split my order across multiple designs or sizes?
Yes. Select 2 designs or 3+ designs in Step 2 of the quote form and note your size breakdown. Your account manager will price the combined run in your written quote.
How long does production take?
Standard production takes 10–14 business days after you approve your digital proof and complete payment. A 4–5 business day rush option is available at an extra cost quoted per order.
Do custom mailer boxes ship flat?
Your account manager confirms packing and delivery details with your written quote.
Still have a question? Ask a packaging specialist.
Request a Quote →Parts of a mailer box
- Roll end tuck front (RETF)
- A one-piece corrugated mailer with rolled double side walls and a front-locking lid
- Cherry locks (locking ears)
- Rounded tabs on the ends of the front tuck flap that slot into the front wall
- Dust flaps
- Side flaps hinged to the lid that tuck inside the tray walls to block dust
- Rolled side walls
- Side panels that fold over 180 degrees and lock into the base floor for double wall strength
- Flute
- The wavy corrugated inner arch sandwiched between two flat linerboard sheets
- Dieline
- The flat cutting and scoring template used to manufacture and print the box
Other box styles
Learn more about mailer boxes
Get your mailer boxes price
One dedicated account manager prepares pricing across up to 3 quantities.
- Free design & AI-to-print studio + 3D mockup
- No die or plate charges · 4–5 day rush available
- Free shipping to all 50 states
- 10% off your first order
- Reprint or refund if we get it wrong
The roll end tuck front (RETF) construction, part names, and comparisons were verified against FEFCO 0427 corrugated standards and independent structural dieline documentation. The dieline sketch is drawn from the verified 2-source geometry, and a packaging specialist checked every specification against CubitPack offerings. Spot something wrong? Tell us and we fix it. Tell us if something looks wrong.
Sources
- FEFCO 0427 self-locking die-cut corrugated mailer structure, rolled double side walls, and front locking ear geometry
- Roll end tuck front (RETF) corrugated mailer panel layout, side dust flaps, cherry locks, and glue-free assembly sequence
- E-commerce corrugated mailer box inside-and-outside print zones, insert compatibility, and flat-shipped storage behavior
What changed
- October 24, 2026: Published with verified RETF construction facts, custom dieline and assembly drawings, 15 studio images, and three supporting guides.