Tab Lock Mailer Boxes
Tab lock mailer boxes — the standard e-commerce mailer. A die-cut tab pushes into a matching slot and stays there, holding the lid closed through the courier network without tape.
- Positive mechanical closure, no tape required
- Shows visible evidence if the box has been opened
- One-piece corrugated, ships and stores flat
- E-flute for light goods, B-flute or double wall for heavier
- From 50 units, full-colour print inside and out
- 4–6 working daysClock starts at proof approval
- Artwork checked firstBleed, folds and colour build
- Nothing prints unapprovedYou sign the proof first
- Curbside recyclableUnless you choose a laminate
Get a quote for
tab lock mailer boxes.
Send the dimensions of the product rather than a box you already use — we add the clearance ourselves. Itemised pricing comes back the same working day.
- Priced at several quantities, so you can see where the curve flattens
- Print-ready dieline and a 3D render, at no charge
- We flag it if a smaller dimension would cost you less
| Box style | Self-locking mailer box (Roll End Tuck Front — RETF) |
|---|---|
| Material options | Kraft corrugated, white corrugated, E-flute, B-flute, rigid stock (premium) |
| Flute types | E-flute (1.5mm), B-flute (3mm), custom flute on request |
| Stock thickness | 16pt – 28pt (depending on material selection) |
| Printing options | Offset printing, digital printing, flexographic printing |
| Color options | CMYK (4-color process), Pantone (PMS), inside & outside printing available |
| Finishing options | Matte lamination, gloss lamination, soft-touch lamination, AQ coating |
| Add-ons | Spot UV, foil stamping (gold/silver), embossing, debossing, custom inserts |
| Sizes | Custom sizes available (length × width × depth) |
| Minimum order qty | Low MOQ available — start at 50 units |
| Turnaround time | 4–6 business days (rush available) |
| Shipping | Flat-packed, free shipping available across the USA |
| Eco-friendly | Recyclable & biodegradable options available |
Tab lock mailer boxes — the standard e-commerce mailer. A die-cut tab pushes into a matching slot and stays there, holding the lid closed through the courier network without tape.
- Positive mechanical closure, no tape required
- Shows visible evidence if the box has been opened
- One-piece corrugated, ships and stores flat
- E-flute for light goods, B-flute or double wall for heavier
- From 50 units, full-colour print inside and out
If you have received a subscription box or a direct-to-consumer parcel in the last few years, it was probably a tab lock mailer. A tab die-cut into the lid pushes through a slot in the front wall and stays engaged under tension. It is the default for a reason: it holds well, needs no tape, and assembles in seconds.
What the closure actually does
The tab is doing two jobs. It holds the lid shut, and it holds the front wall square — which is what keeps the box from splaying when it is stacked or squeezed in a delivery van. That second job is why a tab lock feels more solid in the hand than a tucked mailer of the same board.
It also gives you tamper evidence for free. Disengaging the tab leaves a visible crease, so a customer can tell whether a box has been opened before it reached them.
Where it can go wrong
Two failure modes, both avoidable. An oversized box lets contents shift, which flexes the front wall and works the tab loose — the fix is sizing to the product, not a stronger closure. And repeated opening tires the slot, so if the box is meant to be reused or returned, a tuck top closure holds up better over several cycles.
Our guide on how to measure a mailer box covers the clearance figures that keep a tab lock seated properly.
Board and print
E-flute is standard and prints crisply. Step up to B-flute for heavier contents or longer journeys — the closure is unchanged, only the wall thickness. Full-colour printing is available on both faces, and an inside print is one of the cheapest ways to make the opening moment feel considered.
Frequently asked questions
Does it need tape?
No. That is the point of the construction, and it is a meaningful saving in labour and consumables at volume.
Is it secure enough for valuable items?
The closure holds firmly and shows tampering. For genuinely high-value goods, add a tamper-evident seal over the tab.
Can the tab be printed?
Yes, and a short message on the tab is a nice detail that costs nothing extra on a job already printing in colour.
Get it sized properly
Send the product dimensions and weight. We add the clearance, pick the board, and return a dieline with the tab geometry already resolved.
How we build tab lock mailer boxes.
Measured from the product
We size the box around what goes inside and add the clearance it needs. That removes void fill you would otherwise buy and dimensional weight you would otherwise pay on every order.
Colour that behaves
Process CMYK or a Pantone spot match, outside and in. We tell you how a colour will sit on kraft before the run, not after it.
Board matched to the load
E-flute, B-flute or double wall depending on weight and fragility. We will talk you down a grade as readily as up one.
Assembles in one motion
One-piece construction with a front-tab lock. No tape, no gun, and seconds rather than minutes at the packing bench.
Recyclable as standard
Kraft and corrugated go in the curbside bin with water- and soy-based inks. Plastic lamination changes that, and we say so when you ask for it.
Fifty is a real run
Enough to prove a design before committing to thousands. Pricing steps down at 250, 500 and 1,000 as setup cost spreads.
Customization options
Board, print method and finish are three separate decisions, and each one moves the price. We will tell you which are worth paying for on your product and which are not.
Stock & flute
Printing
Finishes
Add-ons
Brands that ship with this box
What customers tell us
"The print quality is unreal and the fit around our product is perfect. Our unboxing posts doubled."
"Low minimum let us test, and the design team caught issues before print. Reordered at 5,000."
"Boxes arrived early, flat-packed and flawless. Free shipping made the math easy. Highly recommend."
