Custom Roll End Tuck Top Boxes, Printed Inside and Out

What is a roll end tuck top box?

Picture the sturdy little box a subscription brand sends each month. That is usually a roll end tuck top. One flat sheet of corrugated board folds into a tray with a lid attached.

The ends give the style its name. Each end panel turns over onto itself, which makes that wall two layers thick. The lid then closes over the top and tucks in at the front.

Why do the ends roll over?

The rolled ends add stiffness exactly where a mailer takes the most knocks. They also hide the raw cut edges of the board, so the box looks clean from every angle.

Small pockets form where the layers meet, and these hold the box square. That is how it stays rigid without any glue.

Stack a few cartons in a delivery truck and the corners hold their shape. The lid still lines up when your customer opens it.

How does it compare with other mailer styles?

We make several mailers, and each suits a different job. The table below shows how this one differs, so you can pick the right fit.

If you ship light items in large numbers, a simpler tuck top mailer for light items can be quicker and cheaper to fold. Choose rolled ends when the box has to feel solid.

What size roll end tuck top should I order?

Measure the product, then add anything else that goes in the box, such as tissue, a card or an insert. Send us the inside length, width and height in inches.

Use inside dimensions only. We add the board thickness and the extra fold at the ends when we draw the flat layout.

Avoid ordering a box much deeper than your product. Extra space lets items slide around in transit. This simple guide to measuring a box shows where to place the tape.

Which board should I choose?

E flute, about 1/16 in (1.5 mm), is the usual pick. It folds sharply, stays slim and gives a smooth surface for print.

B flute, about 1/8 in (3 mm), adds padding for heavier or more delicate contents. The rolled ends get noticeably stiffer in this thickness.

Then choose the outer face. White paperboard shows full color artwork at its brightest. Kraft gives a natural look that suits one or two color logos.

Candles, glass bottles and ceramics lean toward B flute. Cosmetics, soap and apparel do fine in E flute. Our flute guide comparing board thicknesses lines them up side by side.

How should I print the box?

Most of the impact comes from the inside. Lift the lid and the whole interior is on display, so a bold pattern or message there pays off.

Many brands keep the outside quiet with just a logo. That also keeps the carton low-key on a porch.

Matte or gloss lamination, spot UV and foil all work on the lid. Keep them clear of the fold lines, where coatings can crack.

A short note under the lid, like a care tip or a thank you, is a nice touch. Buyers often photograph it. For more options see our custom printed box range.

How do I order, and what does it cost?

Email or message us on WhatsApp with your inside size, board and artwork. Our designers place everything on the flat layout and send a free proof.

If you have not used mailers before, tell us what you ship and roughly how heavy it is. We will suggest a flute and depth.

Prices start from $0.30 a box, and the exact figure arrives in your quote by email within one business day. Low minimums are quoted per job. You can request a quote by email at any time.

After you approve the proof, production takes 4–6 business days. Shipping to any US address is free and tracked, and takes 2–3 business days. Report misprints or damage within 10 days with photos for a reprint or refund.