Custom Double Wall Tuck Front Boxes for Heavy Orders

What is a double wall tuck front box?

It is a folding mailer made from one sheet of corrugated board. The lid hinges at the back, and the front flap slips inside the base to close.

Most boxes in this style use single wall board. This one uses BC flute, which stacks two flutes between three liners for about 1/4 in of total thickness.

If your goods are lighter, our standard printed mailer boxes may be enough.

Is double wall worth it compared with single wall?

For heavy or breakable goods, usually yes. The extra flute adds cushion, and the rolled sides already double up the board at the walls.

There is a cost in bulk. Double wall folds less tightly, so a very small box can look chunky. Under about 6 in long, single wall tends to look neater. Read our guide on single wall versus double wall board before you decide.

Can I print on the inside and outside of the box?

Yes. The underside of the lid is the first thing a customer sees. Sellers often put a thank you note, a pattern or a care card there.

We print plain, one color, two color or full color CMYK. Solid color boxes look sharp in this style, and a single logo on kraft is a favorite for craft brands.

Matte or gloss lamination, spot UV, foil stamping and embossing are all available. Our designers help with layout for free, and you see a free proof before anything is printed. Browse more custom printed boxes for other styles.

Do I need an insert inside a double wall mailer?

For one heavy item, the thick walls may do the job alone. For sets, or for glass pieces that must not touch, an insert holds each one still.

Corrugated inserts give the most cushion. Folding carton inserts are lighter and take print, which suits gift sets where the layout is part of the look. See our packing supplies and inserts for options.

Tell us how much each piece weighs when you request a quote. A full bottle needs a deeper cradle than an empty-looking jar of the same height.

Folding and closing a tuck front box, step by step

Lay the flat box with the print side down. Raise the front and back walls, then roll the side panels over and press the locking tabs into the base slots.

Place the goods and fold the dust flaps over them. Bring the lid across and push the front tuck flap down inside the front wall. The side ears lock the lid.

Many shippers add a strip of tape or a sticker across the front edge. It adds security and shows the box was not opened in transit.

Thick board needs firm creases the first time. After a dozen boxes, most packers fold one in under a minute.

What mistakes should I avoid with double wall mailers?

The first is picking double wall for a tiny box. Heavy rolled walls can make the lid hard to close.

The second is ignoring the outer size. A box that fits your goods may land in a higher shipping rate bracket. Our guide to the cheapest way to ship boxes explains how size affects cost.

The third is placing artwork near the folds. Thick board takes more room at each crease, so keep small text well back from the edges.

Last, leave a little extra length at each end. The dust flaps need space to lie flat over the goods.

Turnaround time for double wall tuck front orders

Once you approve the proof, we need 4 to 6 business days to produce the order. Shipping is free and tracked to any US address, and transit takes 2 to 3 business days.

Boxes arrive flat, so even a large order fits on a shelf. Read our shipping information for details.