Roll End Tuck Top (RETT) Mailer Dieline Generator
Generate production-ready parametric dielines for Roll End Tuck Top corrugated mailers. Engineered with self-locking rollover sidewalls, bottom locking tab slots, friction ear flaps, and zero glue requirement. Export to PDF, DXF, and SVG.
Anatomy of a Roll End Tuck Top Mailer
The RETT mailer is the king of subscription box unboxing experiences and DTC shipping. Created from a single sheet of corrugated cardboard, it provides triple-wall stacking strength along its sides without adhesive tape or glue.
1. Double-Wall Rollover Sides
The side panels rise upright and then fold 180° inward over the front and rear corner flaps. Protruding tabs at the bottom of the inner walls snap securely into die-cut slots in the base, locking the box frame into a rigid structure.
2. Friction-Fit Lid Wings
Hinged along the sides of the top lid, contoured wings slide down between the inner and outer side walls. They act as dust barriers and provide vertical crush resistance when boxes are stacked during shipping.
3. Front Tuck Flap & Locking Ears
The front tuck flap features optional rounded corner heads and locking ear tabs (cherry locks) that provide a snug friction fit inside the front wall, keeping the mailer firmly closed in postal handling without external tape.
4. Zero Glue or Tape Requirement
100% mechanical snap-lock assembly. Reduces packaging assembly labor on fulfillment lines, cuts packing tape costs, and delivers a clean unboxing experience.
Mailer Technical Specifications
- FEFCO Standard:FEFCO 0427 / 0426
- Recommended Flutes:E-Flute (1.5mm) / B-Flute (3.0mm)
- Crush Resistance:200 lb+ Edge Crush Test (ECT)
- Prepress Bleed:3.0 mm (1/8 in) Outward Offset
- Assembly Time:~10 seconds (no tape/glue)
- Cutter Formats:AutoCAD R12 DXF, 1pt PDF, SVG
E-Commerce Applications
Step-by-Step Assembly Instructions
Raise Front & Rear
Fold front and rear walls 90° upright, and bend the 4 corner flaps 90° inward along the sides.
Roll Over Side Walls
Raise the outer side walls upright, then fold the inner side walls 180° over the corner flaps into the box.
Snap Locking Tabs
Press the bottom tabs of the inner walls firmly into the die-cut slots in the base until they snap locked.
Fold Lid & Tuck
Pre-fold the lid wings and front tuck flap downward 90°, swing the lid shut, and slide the tuck flap into the front.
Generate Your Custom RETT Mailer Dieline
Test your e-commerce mailer in real-time 3D simulation with custom artwork, and export CNC-ready DXF and PDF cutlines.