Tuck top mailer boxes are the choice for brands that want the efficiency of a mailer format with the premium presentation of a tuck-end retail box. They ship flat, assemble in seconds, and arrive at your customer's door looking polished, intentional, and brand-confident.
Free Shipping Across USA
Offset/Digital printing
Free Design Support
Custom Finishing
The tuck top mailer box bridges the gap
between a standard mailer and a retail gift box. It has the structural strength
and protective performance of a corrugated mailer, with the clean exterior
print surface and tuck-end closure of a premium retail box. For e-commerce
brands that want every delivery to feel like an event, this format delivers.
We produce tuck top mailer boxes in custom
sizes with full-colour exterior print and the full finish range. The tuck top
closure creates a clean, professional opening experience — no tape, no sealed
edges, just a clean lift-and-open that sets the tone for the unboxing moment
that follows. Interior printing options add an additional brand touchpoint on
the inside lid.
For subscription box brands,
direct-to-consumer product launches, and premium e-commerce operations that
treat every delivery as a customer experience, tuck top mailer boxes are the
format of choice. Consistent quality, reliable flat-pack storage, and fast
turnaround make them a practical as well as a premium choice.
|
Structure |
Tuck top with full dust
flap / interlocking base closure |
|
Board |
Single-wall corrugated or
400gsm+ rigid board |
|
Print |
Full-colour exterior and
optional interior |
|
Assembly |
Flat-packed for storage /
quick-fold assembly |
|
Sizes |
Fully custom |
|
MOQ |
LOW MOQ |
|
Lead Time |
10–15 business days |
Board and Structural
Materials
◆
Corrugated
E-Flute (mailer grade)
◆
Rigid SBS 400gsm+
(premium format)
◆
Kraft Board
Interior, Lining and Insert
Options
◆
White or kraft
interior
◆
Custom-printed
interior lid and base
Available Print Finishes
◆
Gloss Lamination
◆
Matte Lamination
◆
Spot UV
◆
Foil Stamping
◆
Aqueous Coating
|
Print
Method |
Description
and Best Use |
|
Digital
Printing |
Best for short runs,
prototypes, and variable data. Full-colour CMYK. Fast turnaround with no
plate setup cost. Ideal for samples and limited editions. |
|
Offset
Lithography |
Gold standard for colour
accuracy on medium to large volumes. Pantone PMS spot colour matching. Best
for brand-critical retail packaging. |
|
Flexographic
Print |
Cost-efficient for
high-volume corrugated and kraft packaging. Up to 6 colours. Best for food
boxes, mailers, and large-format packaging runs. |
Colour System
CMYK four-colour process as
standard. Pantone PMS spot colour matching available on all offset print runs.
White ink available for printing on kraft, black, and dark-coloured boards.
Artwork Requirements
Preferred format: press-ready
PDF. Also accepted: AI, EPS, PSD. Minimum resolution 300 DPI at 100% print
size. Bleed allowance 3mm all sides. Safe zone 3mm inside trim edge. Embed all
fonts and links before submitting.
Proofing and Approval
Full-colour digital PDF proof
provided for every order before production. Physical die-line and printed
samples available on request. Production commences after written proof
approval.
Note: Interior
printing on lid and base panels available for premium unboxing experience.
Full-colour exterior across all six panels.
Yes, we offer sample kits and paid custom samples so you can verify the structure and print quality before a larger run.
Our minimum order quantity starts as low as 50 units for standard boxes, allowing you to test the market effectively.
You need a print-ready file (AI or PDF). If you don't have a designer, you can download our dielines and use Canva or Adobe Illustrator to place your logo. We review every file before printing.
Standard production takes 7-10 business days. Shipping time depends on your location and the shipping method selected at checkout.
Absolutely! We specialize in engineered custom packaging. Please fill out the custom quote form below with your specific dimensions.
End-to-end payments and financial management in a single solution.
Get Your
Structure Packaging engineers premium custom solutions, turning your unboxing into a brand asset. We are committed to load-bearing integrity, sustainable materials, and factory-direct speed with every shipment.