FEFCO 0427
Mailer box: blank size calculator and dieline
The e-commerce mailer, also called a roll end tuck top. One piece, no glue: the side walls roll in, the lid folds over them and tucks in at the front. It ships flat and is closed by hand.
Blank size calculator
Why there is no formula here
There is no exact formula on this page, on purpose. The ear locks and dust flaps are capped so they never get longer than the box allows, and that cap kicks in at different sizes for different boards. A straight-line formula is up to 90 mm off on larger boxes.
The calculator above runs the generator itself, so the size it gives is the size of the file.
Per board
The same 300 × 200 × 80 mm inside on each board. Thicker board means a bigger blank for the same inside size.
| Board | t (mm) | Blank (mm) |
|---|---|---|
| F-flute | 0.8 | 635.4 × 644.8 |
| E-flute | 1.5 | 645.6 × 649 |
| B-flute | 3 | 668.8 × 658 |
| C-flute | 4 | 684.8 × 664 |
| EB double wall | 4.5 | 693.2 × 667 |
| BC double wall | 7 | 732.8 × 682 |
In the generator
Not to be confused with
- FEFCO 0201
- A slotted box has a glued joint and is closed with tape; a mailer needs neither.
Questions
- Why is a mailer blank so much bigger than the box?
- The side walls are rolled, so they are two layers of board, and the lid, tuck flap and ears all come out of the same sheet. The 300 × 200 × 80 mm mailer on E-flute at the top of this page needs a blank of about 646 × 649 mm.
- What is the difference between the mailer variants?
- Ear locks, a slot lock, no dust flaps, or a plain flap that is closed with tape. They all share the 0427 construction; the links below open each one in the tool.