Corrugated shipping boxes / JETDIELINE

Mailer with locking tabs

Corrugated mailer with double side walls and an external tuck closure. The lid locking tabs engage through oblong holes in the front wall; the construction is erected without gluing.

Mailer with locking tabs — Dieline preview of the documented example. Set the dimensions and production material in JetDieline.

Interactive 3D fold view

03 / BOX

Simplified display model without material thickness, not to scale.

Template ID: corrugated.mailer.lock
Construction: Corrugated shipping boxes
Current template version: V1
Dieline preview version: V1

How the shape is constructed

Corrugated mailer with double side walls and ears like the mailer box; the lid overlaps the outside of the front wall with a closure flap whose locking tabs snap into slots in the front wall. No gluing, can be opened repeatedly.

How it is assembled

Erect the front and back walls and fold the ears inwards. Erect the side walls, fold the turnover and inner wall over the ears and insert the tabs into the bottom slots. After filling, fold in the lid dust flaps, close the lid, place the closure flap against the outside of the front wall and insert the locking tabs through the slots.

Material and grain direction

Flute direction parallel to the blank’s y-axis: double-wall creases fold neatly, lid hinge and tuck flap remain stiff (check with the test printer).

Test fit, folding and closure on a sample made from the intended material. Confirm material thickness, grain direction and production steps with your printer.

Dimensions of the illustrated example

250 × 180 × 80 mm

25 × 18 × 8 cm9.84 × 7.09 × 3.15 in / ″

Length: 250 mmWidth: 180 mmHeight: 80 mm

Inside dimension

These dimensions describe the preview, not a fixed packaging size. The app recalculates the dieline for your own dimensions.

What to consider for this construction

Rollover width

Width of the double wall's rollover (crease-to-crease); holds the flaps in the pocket.

Flap gap

Gap between adjacent flaps or walls; at least about the material thickness.

Ear length (ratio)

Length of the ears or corner flaps as a proportion of half the inside width.

Lid dust flaps (ratio)

Length of the lid dust flaps as a proportion of the inside height.

Dust flap angle

Angle of the dust flaps (also the ears on a mailer); larger angles prevent collisions during folding.

Frequently asked questions

Which tabs hold the lid?

The parameters closureTabCount, closureTabWidth and closureTabDepth describe the locking tabs on the outer closure flap. The lockTab parameters belong to the double side walls and their bottom slots. Both groups are visible in the same dieline but serve different purposes. Check wall assembly and lid closure separately.

Does this mailer need adhesive?

The assembly from the source code erects the front and back walls, folds in the ears and locks the side walls into the base. The lid closure then engages through the front wall. No gluing is intended for this structure. Whether additional transport securing is needed depends on the shipping workflow and has not been confirmed by calculation.

Why can the closure flap not be arbitrarily deep?

The tabs engage through slots in the front wall. Material must remain below these slots down to the bottom crease. closureDepth.atMost.slotAboveBottom therefore limits the depth. A larger value may weaken the wall or prevent assembly; check height and closure changes together.