Free tool · by Dharaksha
Mailer box template: free mailer box dieline generator
Create a roll end tuck front mailer box dieline for e-commerce and subscription boxes. Enter the inside size, choose E-flute or B-flute corrugated board, and download a true-scale PDF, SVG or DXF.
Mailer box template
What is a mailer box?
A mailer box is the sturdy, book-style shipping box used by e-commerce and subscription brands. It is cut from one piece of corrugated board: a base, a back wall with a hinged lid, a front wall, and side walls that roll over to form double walls. Locking tabs on the rolled walls click into slots in the base, and the front of the lid tucks in. It folds without glue or tape.
The double side walls make the mailer strong for its weight, and the clean, flat lid is ideal for a printed logo and an unboxing message inside. This template draws the classic roll end tuck front (RETF) style, also called a roll end front tuck mailer.
How the mailer box dieline is sized
The board thickness matters more in a mailer than in a carton, because the side walls are doubled and the lid wraps over them. The generator makes the base the inside length and width plus three board thicknesses, and the walls the inside height plus one thickness. With 1.5 mm E-flute, a 250 × 180 × 80 mm mailer has a base of 254.5 × 184.5 mm and 81.5 mm walls.
The lid is slightly narrower than the base so it closes inside the rolled walls, the front tuck is sized from the height, and the locking slots sit half a board thickness in from the fold. Choose B-flute (3 mm) for heavier products and the allowances grow automatically.
Good uses for a mailer box
Direct-to-consumer shipping, subscription and gift boxes, clothing and shoes, books, cosmetics sets and electronics accessories. To protect fragile items inside, design a matching mycelium insert in the second tab of the tool: it gives 3× the shock absorption of thermocol (EPS) at equivalent density and is home compostable in about 60 days in soil.
Artwork tips
The inside of the lid is the first thing a customer sees, so many brands print a message or pattern there as a second print side. On the outside, the lid and the front wall carry the logo. The rolled inner walls are hidden once the box is closed, so keep important artwork off them.
Example sizes to start from
Pick a size to load it into the generator above, then change it to fit your product. These are starting points, not standards.
| Example | Inside size (L × W × H) | Board | Generator |
|---|---|---|---|
| Small accessories mailer | 160 × 120 × 50 mm | 1.5 mm | Open this size |
| Standard e-commerce mailer | 250 × 180 × 80 mm | 1.5 mm | Open this size |
| Clothing mailer | 320 × 240 × 80 mm | 1.5 mm | Open this size |
| Heavier products, B-flute | 300 × 220 × 120 mm | 3 mm | Open this size |
Need a different style? Go back to the box dieline generator to switch between all six, or open another template below.
FAQ
Mailer box template: questions, answered
What is the difference between a mailer box and a shipping box?
A regular shipping carton has flaps that meet in the middle and need tape. A mailer box has a hinged lid, rolled double side walls and a tuck front, so it closes without tape and opens like a book, which makes it better for presentation.
Which flute is best for a mailer box?
E-flute (about 1.5 mm) is the most common choice for printed mailers because it is thin, strong and takes print well. B-flute (about 3 mm) is stronger for heavier products and rougher courier handling.
Can I use the mailer box template in Canva or Illustrator?
Yes. Open the PDF or SVG in Illustrator, Affinity or Inkscape and keep the dieline on its own locked layer. In Canva, upload the PDF or SVG and use it as a guide under your design.
Do I need glue for this mailer box?
No. The rolled side walls lock into slots in the base and the lid tucks into the front, so it assembles without glue or tape.
Will a 3 mm board change my mailer dieline?
Yes. Change the material to B-flute or enter your own thickness and the base, walls, lid and tuck all update to match.
Ready to move your packaging off plastic?
Send us your dieline spec and we will quote a mycelium insert or moulded pack to match, with samples to test on your own line.