What a mailer box is for
Mailer boxes are the default for direct-to-consumer brands, subscription services, and premium unboxing. Their sturdy, self-locking construction protects the product in transit, and because the interior is printable they turn opening the parcel into a branded moment. The most common structure is the roll-end front tuck with dust flaps.
How the mailer folds
A mailer box is a single flat blank whose side walls fold up and lock, with a front tuck and dust flaps that hold everything closed. The dieline shows each panel laid flat — base, walls, lid, and tuck — so your artwork lands in the right place before the box is folded.
Common mailer box sizes
- 6×4×3 in
- 9×6×2 in
- 12×9×4 in
- 18×12×6 in
Design it in Pack AI
Upload the dieline your manufacturer sent and Pack AI detects each panel automatically — or let the AI dieline generator draft a layout. Add text, logos, and colors panel by panel, then export the format your printer wants — PDF at 300 DPI, SVG, or Adobe Illustrator.
Frequently asked questions
What are common mailer box sizes?
Frequently used mailer sizes include 6×4×3, 9×6×2, 12×9×4, and 18×12×6 inches — small formats for jewelry and cosmetics up through larger apparel and multi-item boxes.
Can I print on the inside of a mailer box?
Yes — the printable interior is one of the mailer box's main advantages, and Pack AI lets you design the inside panels of the dieline as well as the outside.
Other box types