Custom Tuck Top Mailer Boxes

Updated 2026-10-05

Custom tuck top mailer boxes are corrugated or paperboard mailers whose lid tucks into the front panel, creating a clean closure for shipping and retail use. Brands use them for apparel, cosmetics and subscription kits. Choose E-flute or paperboard, kraft or white, with printing inside and out. Send your dimensions and Vorex replies with pricing.

Lid tucks in for neat closure
Opens without a knife
Custom printed inside and out
Kraft or white board

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What makes a tuck top mailer box different

A tuck top mailer box has a hinged lid with a front flap that slides into the front wall, often with locking side ears that hold the lid firmly shut. The result is a box that closes securely, stays neat on the shelf and opens with one easy lift. Tuck top mailer packaging bridges shipping and presentation, so it fits brands that send products directly to customers and also sell at markets or in stores.

For shipping, E-flute corrugated is the usual choice because it balances protection with a slim profile. For lighter products sold in retail settings, rigid-feeling paperboard such as SBS can work well. Kraft board gives an organic look, while white board shows color most accurately. If your item is heavy, ask about a tuck top with an auto bottom, which keeps the base locked when the box is lifted.

The front tuck flap is a strong branding spot because it sits right where the thumb lifts the lid. Many brands print a small message or logo there. Keep the lid artwork centered and leave safe margins around the fold lines. Custom printed tuck top boxes can also carry a pattern on the interior walls. Our team will set your design on the dieline and send a digital proof for approval.

Popular uses

Apparel and accessory shipments
Beauty and skincare kits
Subscription and sample boxes
Gift sets for markets and pop-ups
Small electronics accessories
Candles and home goods

Specifications

Size	Made to your exact inside dimensions (L × W × H)
Materials	Paperboard (SBS), kraft, corrugated (E, B or double wall), rigid chipboard
Printing	Full colour CMYK, Pantone (PMS) spot colours, inside and outside printing
Finishes	Matte, gloss or soft-touch lamination, spot UV, foil stamping, embossing, debossing
Add-ons	Window cut-outs, inserts, handles, custom tissue paper and stickers
Proof	Digital proof on your dieline before production

Request pricing for custom tuck top mailer boxes

Make it yours

Options for custom tuck top mailer boxes

Closure styles

Choose a standard tuck top with dust flaps, a tuck top with locking ears for a firmer close, or a tuck top auto bottom for heavier items.

Materials

E-flute corrugated for shipping strength, or SBS paperboard for lighter retail products. Both come in kraft or white surfaces to suit your brand palette.

Printing

Print your logo and artwork on every outside panel, inside the lid and on the tuck flap, using full color or a focused one- or two-color design.

Finishes

Choose matte or gloss coating, or ask about soft-touch lamination, spot UV and foil stamping on white board for a more premium presentation.

Inserts

Add paperboard or corrugated inserts with cutouts so bottles, jars and accessories sit upright and stay in place when the box is moved.

Eco options

Kraft board and corrugated are paper-based and widely recyclable where facilities exist. Ask about recycled-content board and water-based inks. Kraft also suits brands that want a natural look.

How it works

Ordering custom tuck top mailer boxes

Get a free quote

Request a quote
Tell us the box style, size, quantity and where it ships.
Get pricing and a proof
A specialist confirms options and sends a digital proof of your design.
Approve and print
Nothing goes to press until you approve the proof.
Delivered to your door
Boxes ship to your address in the USA or Canada.

FAQ

Custom Tuck Top Mailer Boxes: questions answered

Still unsure? Ask a packaging specialist.

What is a tuck top mailer box?

A tuck top mailer box is a folding box with a hinged lid whose front flap tucks into the front panel to close. It often has locking side ears for extra security. It ships well and presents neatly, which makes it popular for ecommerce and gift sets.

Is a tuck top mailer box strong enough to ship?

When made from corrugated board, a tuck top mailer can ship on its own for most lightweight and medium products. For heavy or fragile items, a specialist may recommend B-flute or an outer shipper. Share your product weight for a recommendation.

Can I put a tuck top box in a poly mailer?

Yes. Many brands place a paperboard tuck top box inside a poly mailer or bubble mailer for shipping. This keeps the printed box clean and dry. If you want the box to ship on its own, choose a corrugated version instead.

What is the difference between a tuck top box and a tuck end box?

A tuck top box opens from a hinged lid on the large top panel, like a mailer. A tuck end box opens from the narrow ends, like a typical retail carton. Tuck top styles suit flat items and kits, while tuck end styles suit tall products.

How do I order custom tuck top mailer boxes?

Send your box size, quantity, material preference and artwork through the quote form. A Vorex specialist replies with pricing, offers design help if needed, and sends a digital proof so you can approve every panel before production.

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