A folded mailer—often called a mailer box—is a die-cut paperboard/corrugated box shipped flat and quick to fold/self-lock for e-commerce and PR kits. It balances strength, assembly speed, and branding.
Structures
RETT (Roll End Tuck Top): fast tuck-top closure for light–medium loads.
Front-lock / self-locking styles: stronger front catch; tape-free close.
Double-wall/rolled edges: reinforced rims for crush and tear resistance.
Size notation: use L × W × H (internal); L/W = opening panel, H = box depth.
Materials
Corrugated:
E-flute (~1.5–2.0 mm): finer print, sleek look.
B-flute (~2.5–3.0 mm): higher stacking and cushioning.
EB-double wall: strength + better print flatness.
Facings: kraft, white top-liner, or SBS/FBB laminates; FSC/PEFC available.
Print & Finish
Kraft + 1–2 colors for value and eco feel.
Full-bleed CMYK (with litho-lam or premium liner) for brand impact.
Options: spot UV, foil, emboss/deboss, lamination (gloss/matte/anti-scuff), AQ. Favor recyclable finishes for shipper boxes.
Performance
Compression & stacking depend on flute, board grade, grain, humidity.
Shock protection pairs with inserts (pulp, paper, foam, honeycomb).
Moisture/tear upgrades: wet-strength liners or coatings (mind recyclability).
Typical Uses
E-commerce shipping, subscription/PR kits, returns/exchanges (add tear-strip + reclose tape), books, apparel, beauty, accessories, small devices.
Design Tips
Prioritize fit + cushioning to avoid bulging/voids.
Enhance unboxing: tear-strip, reclose tape, pockets, QR/story print inside lid.
Heavier loads (>2–3 kg or long side >40 cm): choose B/EB or higher board grade.
Supply dieline artwork (AI/PDF), mark internal size, crease direction, and finishes; 300 dpi images, separate layers for spot colors/foil.
Sustainability
Recycled content options; water-based coatings and solvent-free adhesives.
Prefer recyclable laminations or go coat-only to keep mono-material.
Ships flat → reduces freight volume and storage footprint.
Purchasing & Lead Time (typical)
MOQ: ~100–500 pcs; 500+ improves unit cost.
Sampling: cutter-guide + white mockup 3–7 days; mass run 7–15 days (complex finishes/holidays extend).
Quote drivers: internal size, board spec (liners/flute), print colors, finishes, quantity, destination, sampling.