Custom Tuck Top Mailer Box

Packaging That’s Secure, Convenient & Brand-Ready

Ideal for shipping small to medium products, our tuck top mailers offer quick assembly and a neat, professional look.

Strong Materials That Protect Your Products

• E-flute or B-flute corrugated board – Provides cushioning and crush resistance
• White kraft or natural kraft finishes – Choose from clean or eco-friendly aesthetics
• Optional moisture-resistant coatings – For added product protection
• Smooth surfaces ready for vivid printing

Custom Sizes and Styles Tailored to Your Needs

• Standard tuck top flap with easy closure
• Auto-lock bottom for added strength and speed of packing
• Flat-fold design for space-saving storage
• Optional inserts or dividers for product protection and organization

Branding and Print That Boosts Recognition

• Full-color CMYK or spot Pantone printing
• Space for logos, product info, and promotional messages
• Matte, gloss, or soft-touch finishes available
• QR codes for customer engagement and tracking

Functional Features That Improve User Experience

• Easy-to-tuck flaps for secure closure
• Tear strips or perforations for easy opening
• Space for shipping labels and handling instructions
• Eco-friendly and recyclable material options

The 3Ps of Tuck Top Mailer Box Packaging

Presentation

Clean, branded designs that deliver a positive first impression.

Preservation

Durable construction and coatings keep products safe during transit.

Protection

Secure flaps and sturdy materials prevent damage and ensure safe delivery.

Why 5000+ Brands Trust Us for Mailer Boxes

• No minimum order quantity
• Free dielines and mockups for design approval
• Fast production with U.S.-based shipping
• Sustainable, recyclable materials available
• Expert guidance from concept to delivery

Get a Free Quote Today

Protect and present your products with style and ease.To get cost-effective packaging boxes without compromising on quality, you can contact us at (469) 649-8706 or email us sales@customboxeslab.com

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.