Custom Tuck Top Mailer Boxes Made to Your Size

What is a tuck top mailer box?

A tuck top mailer is a corrugated shipping box with a hinged lid. The lid ends in a flap that slides down inside the front wall.

Before the lid comes down, a dust flap folds in at each side. Those flaps close the corners and keep the top square.

If your product is flatter, browse our full mailer and postal range for other closures.

Tuck top or roll end mailer: which one fits?

A roll end mailer has thick folded end walls, and the lid wraps over them. That shape stays neat but works best when it is low and flat.

A tuck top uses single walls, so height is easy to add. The dust flaps and front tuck hold the lid shut.

The trade-off is one layer of board on each side. That makes the flute choice more important for heavy goods. Items like T-shirts may suit flat roll end mailer boxes better.

How tall can a tuck top mailer be?

There is no fixed limit. The style works best when the height does not exceed the width. Tall, narrow boxes tend to lean and are harder to close.

Measure the product, then add a little room for wrapping. For layered gift sets, measure the whole stack instead of each piece. Our guide on measuring inside box dimensions shows how.

Sneakers are a good example. A pair usually sits heel to toe, so the longest shoe sets the length. Two soles side by side set the width. Tissue on top adds about half an inch.

Which board should I choose for a tuck top mailer?

Think about packed weight first. Because each wall is a single layer, heavier items need thicker board.

Thicker board also holds its shape better if the customer reuses the box for storage or a return. For light goods, E flute folds cleanly and keeps the box slim. Tell us the packed weight and we will suggest a flute. The corrugated board flute guide explains the differences.

How do I get the most from inside print?

A tuck top shows a lot of its inner surface. When the lid lifts, the customer sees the underside of the lid, both dust flaps and the top of the inner walls.

A small repeat pattern works well here. It covers the flaps without awkward fold lines. Plain kraft outside with a bold color inside keeps the package low-key on the porch and makes the opening a moment.

We print plain, one color, two color or full color CMYK, inside, outside or both. Our designers help with layout for free. You can place your logo and artwork in Design Your Box before you order.

Is a tuck top mailer good for returns?

Yes. Few styles are as easy to reuse. The lid lifts without ripping, and the same tuck closes it again.

A buyer can add a fresh tape strip and send the box back. Short return steps printed under the lid help a lot, especially for shoes and apparel. A kraft outside also hides scuffs from a second trip better than bright white.

How do I order tuck top mailer boxes?

Tuck top mailers start from $0.30 a box. The exact figure comes in the quote we email within one business day. Start with the online quote request form, or reach us at info@ordercardboardboxes.com, on WhatsApp or at (503) 461-4788.

After the quote, we send a free design proof. Once you approve it, your boxes are in production for 4 to 6 business days. Tracked shipping then takes 2 to 3 business days and is free to any US address.