Mailer box for an online store: sizes, material and dieline

A box that folds without glue is the standard for shipping clothes, cosmetics and gift sets. How it is built and how to get a template for your product.

BOMBA DESIGN editorialNovember 13, 20267 min read

A mailer box dieline in the BOMBA DESIGN generator — **Mailer box:** base, lid, double side walls and flaps – no glue.

Most online stores selling clothes, cosmetics, candles and gifts ship in mailer boxes. They arrive flat and fold in seconds without glue or tape. The lid opens like a chest – and that is the first moment the customer sees.

The box keeps its shape thanks to double side walls: they fold inwards and lock the flaps. That makes it sturdier than a regular tuck-end box and it handles delivery well.

Key points

A mailer box folds without glue and is stored flat.
Enter outer dimensions, measured along the fold lines.
For shipping, micro-flute 1.5 mm is the usual choice; for light gifts, thick paperboard.

StructureHow a mailer box is built

Part	What it does
Base	The bottom of the box
Front and back walls with ears	The ears tuck inside the side walls
Double side walls	Fold inwards and lock the ears
Lid with three flaps	Closes the box; the front flap tucks inside

SizeHow to choose the size

Measure the product together with the filling: tissue paper, shred or an insert. Add 5–10 mm on each side so it slides in freely. The generator takes outer dimensions along the fold lines: if the inner space matters, add two board thicknesses to each dimension.

Product	Example size, mm
T-shirt, shirt	250 × 200 × 50
Cosmetics set	200 × 150 × 70
Candle, mug	120 × 120 × 120
Book, notebook	230 × 170 × 40

These are examples for reference, not standards. Make a test sample for your own product.

MaterialWhich board to choose

Material	When it fits
Paperboard 0.4 mm	Light gift sets handed over in person
Thick paperboard 0.6 mm	Cosmetics, accessories, small gifts
Micro-flute 1.5 mm	Shipping by post and courier – the most common option
Corrugated board 3 mm	Heavy and fragile products

How-toHow to make a dieline: 4 steps

Open the generatorGo to the box dieline generator and choose Mailer box.
Enter the sizeWidth, depth and height in millimetres.
Choose the materialBoard thickness affects the slots and fold allowances.
Download the filePDF, SVG or EPS for the print shop, DXF for a cutting plotter. PDF on A4 or A3 to print a scaled copy and fold a test box.

DesignWhere to put the logo

On top of the lidThe main spot: the courier and the customer both see it.
Inside the lidA thank-you note, a promo code or social media. Printing inside gives the strongest unboxing effect.
Side wallWebsite or brand name for shelves and warehouses.
No print at allA kraft box with a sticker or a stamp – a budget start for a small run.

HonestlyThe tool gives a template. We design the packaging

The generator builds a standard structure: cut and fold lines and files for the manufacturer. The manufacturer may adjust it to their equipment – always approve the template before the run.

Packaging sells with the eyes. The logo, brand colours and what the customer sees when opening the lid are design. Start with a logo, and we will prepare packaging artwork for print: print design.

Make a test box from an ordinary sheet of paper: print a scaled copy, cut it out and fold it. You see right away whether everything fits.