Tuck-Top & Mailer Boxes
Self-locking, tape-free closures built for e-commerce, subscription boxes, and branded retail. Made in-house with CNC precision - no die fees, no minimums that don't make sense for your run.
When to Use It
Common industries and use cases where this box type performs best.
E-Commerce Shipments
Clean, professional unboxing experience without tape marks or torn flaps.
Subscription Boxes
Branded interior and exterior printing with self-locking lid for premium feel.
Gift & Apparel Packaging
Tuck top closure keeps lids flush and product secure without additional supplies.
Fulfillment Centers
Auto-bottom variants assemble instantly - faster pack rates on the fulfillment floor.
Board Grades
ECT (Edge Crush Test) measures stacking strength. Mullen measures burst resistance. Use ECT for palletized loads; Mullen for rough handling.
| Grade | Mullen Burst | Description | Best For | |
|---|---|---|---|---|
| 32 ECT | 200 lbs | Lightweight. E or B flute recommended. | Apparel, cosmetics, soft goods | |
| 44 ECT | 200 lbs | Standard single wall for most mailers. | General e-commerce, retail | Most Common |
| E-Flute 32 | 150 lbs | Ultra-thin. Exceptional print surface. | Premium branded packaging | Premium |
Flute Options
Flute profile determines thickness, stacking strength, and print quality. We stock all common flutes and produce custom combinations in-house.
E-Flute
Best choice for mailer boxes - thin profile, exceptional print surface, tight fold radius for crisp edges.
B-Flute
Good for slightly heavier products. More rigidity than E with a still-printable surface.
Max Sizes We Produce
All sizes produced in-house on our own equipment - no outsourcing, no lead-time surprises.
CNC vs. Steel Rule Dies
For short runs and custom sizes, the difference is significant. Here's why our CNC-first approach wins.
✓ CNC Cutting (APG)
- Lock tabs and tuck flaps cut to exact tolerance - lids fit perfectly first time
- No die cost means short runs of 25–200 are fully economical
- Adjust box depth without buying a new die setup
- Interior score lines and fold paths are digitally precise
- Same-day prototyping - test the lock fit before running production
✗ Steel Rule Dies
- Steel rule dies for tuck-top boxes are complex - cost $300–$700+
- Lock tab tolerances drift as steel dies wear over high-volume runs
- Changing box size or lock style requires a new die entirely
- Setup time adds 1–2 days before the first production box
- Minimum run quantities of 500+ needed to justify die cost
Ready to Order?
From prototype to production - built in-house in Wylie, TX.