Custom Double Wall Tuck Front Boxes for Heavier Mail Orders

What is a double wall tuck front box?

It is a one-piece folding box with a lid hinged at the back. The side walls roll over on themselves, and the front of the lid tucks down inside the base to close.

Most tuck front mailers use single wall board. This version uses BC double wall, which has two flutes and a total thickness of about 7 mm. The result feels solid in the hand and resists crushing far better.

If you want the lighter single wall version, see our main page on custom printed mailer boxes.

Why choose double wall over single wall for a mailer?

Thicker walls mean more cushioning and more resistance to dents. On a folding mailer, the rolled sides already give two layers of board, so a double wall version has very stiff side walls.

The trade-off is weight and fold. Double wall is heavier and folds less tightly than single wall, so very small boxes can look chunky. For anything under about 150 mm long, single wall is often neater. Our guide to choosing single or double wall board covers this in more depth.

Can I print inside and outside?

Yes. The inside of the lid is a favourite spot for a thank you note or a pattern. The customer sees it the moment the box opens.

We print plain, one colour, two colour or full colour CMYK, on kraft or white outer liners. Coloured boxes in solid shades are very popular for this style.

Matte or gloss lamination gives a smooth surface, and spot UV, foil stamping or embossing can pick out a logo. Layout help from our designers is free, and a free digital proof comes before any print run.

Should I add an insert?

For a single heavy item, the double wall body often does enough on its own. For sets, or for glass that must not touch, an insert keeps each piece in place.

Corrugated inserts give the most cushion. Kraft or white folding board inserts are lighter and print well, which suits gift sets where the layout is part of the look. Browse our packing supplies and box inserts for options.

Tell us the weight of each piece when you ask for a quote. A heavy bottle needs a deeper cradle than a light jar of the same height.

How do I fold and close a tuck front box?

Lay the flat box print side down. Fold up the front and back walls, then roll the side panels over and press the locking tabs into the base slots.

Place the goods, fold the dust flaps in, and bring the lid over. Push the front tuck flap down inside the front wall. The side ears on the lid lock it in place.

For extra security in the post, add a strip of tape or a sticker across the front edge. It also shows the box has not been opened on the way.

After the first dozen, most packers fold one in well under a minute. Double wall board is a little stiffer, so press each crease firmly the first time.

What mistakes do people make with double wall mailers?

One is choosing double wall for very small boxes. The thick board can make the rolled walls look heavy and the lid harder to close.

Another is forgetting how much the outer size grows. A box that fits your goods may slip into a higher postage band.

A third is artwork placed too close to the folds. On thick board, the fold lines take a little more of the panel, so keep text well back from the edges.

Lastly, some sellers order the box but forget the dust flaps need room to fold in. Leave a few millimetres at each end so the flaps lie flat over the goods.

How long does a double wall tuck front order take?

After proof approval, we need 4 to 6 business days to make your boxes. They then go out by tracked delivery and usually arrive in 2 to 3 business days.

We send these free to any address in the UK. The boxes arrive flat, so even a large order takes little room to store.