Die Cut Mailers
Self-locking die-cut mailer boxes for e-commerce.
A die-cut mailer is the DTC standard: it folds from one sheet, locks without tape, and prints inside and out for the unboxing. We cut it to your product.
Add a tear strip or an insert.
- Self-locking, tape-free
- Full-color inside and out
- Cut to your product
- Tear strip and insert options
“Mailers arrived in nine days with the inside print exactly as proofed. Our unboxing videos finally look like the brands we admire.”
“Our cakes travel 40 minutes across town and arrive looking like they left the counter. The window boxes sell them before anyone opens the lid.”
The box the DTC era standardized on
The die-cut mailer earned its ubiquity honestly. It cuts from one corrugated blank, folds and locks with no tape or glue, ships and stores flat, and presents a front-opening lid that swings back like a case, the geometry every unboxing video is framed around. For direct-to-consumer brands it solved packaging, protection, brand moment and operations in one structure.
Anatomy and options
Self-locking side flaps and a tuck-front lid hold the box closed through courier handling; a peel-and-seal strip adds tamper evidence for higher-value goods, and a tear strip turns opening into one clean pull, with a second seal strip available for returns. Print runs edge to edge, outside and, the format's signature, inside: the open lid and interior walls are the brand's best-seen surfaces. Standard E and B-flute handle most weights; we spec heavier walls for dense products.
The natural partner is a fitted insert, board or foam, staging the product against the printed interior; that pairing is detailed under mailer boxes with inserts.
Sizing is unit economics
Mailer dimensions decide postage band, void fill and freight-in cost simultaneously. We size to your product plus insert clearance, then check the result against carrier rate breaks, a few millimeters often moves a box down a postage band, which repays the design attention on every single shipment. Flat-packed cases keep warehouse footprint minimal, the same logic as our foldable boxes.
What is the minimum for a printed run?
From a few hundred units digitally, full color inside and out. Send product dimensions and target courier and we spec the blank to both.
