Mailer with locking tabs

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.

Shipping

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Dieline: Mailer with locking tabs — Vector preview from the catalogue, default dimensions

Dimensions and limits

Default dimensions of the template and the permitted range in mm.

Dimension	Default	Range
Length	250 mm	60–600 mm
Width	180 mm	60–600 mm
Height	80 mm	30–300 mm

Parameters of this construction

14 parameters with default value and limits, adjustable in the editor.

Parameter	Default	Range	Note
Rim width`rimWidth`	10 mm	3–20 mm	Width of the double wall's foldover (crease to crease); accommodates the flaps in the pocket.
Flap gap`flapGap`	5 mm	1–10 mm	Gap between neighboring flaps or walls; at least approximately the material thickness.
Ear length (ratio)`earRatio`	80 %	50–95 %	Length of the ears or corner flaps as a ratio of half the inside width.
Lid dust flaps (ratio)`lidFlapRatio`	70 %	30–95 %	Length of the lid's dust flaps as a ratio of the inside height.
Dust flap angle`dustFlapAngle`	15°	0–30°	Bevel of the dust flaps (also the ears on the mailer); larger angles prevent collisions during folding.
Lock tabs`lockTabs`	on	on / off	Locks the inner walls with tabs in slots in the base.
Number of lock tabs`lockTabCount`	2	1–4	Number of locking tabs per wall.
Lock tab width`lockTabWidth`	25 mm	10–60 mm	Width of a locking tab.
Lock tab depth`lockTabDepth`	6 mm	2–15 mm	How far a locking tab protrudes; at least material thickness plus clearance.
Bottom slot width`slotWidth`	5 mm	1–10 mm	Width of the slots in the base for the locking tabs; at least the material thickness, with clearance from the crease.
Closure flap depth`closureDepth`	30 mm	15–80 mm	Depth of the closure flap outside the front wall up to the locking tab crease; determines the height of the slots in the front wall.
Number of locking tabs`closureTabCount`	2	1–3	Number of locking tabs on the closure flap (one slot each in the front wall).
Locking tab width`closureTabWidth`	25 mm	10–60 mm	Width of each locking tab; the slot is 2 mm longer.
Locking tab depth`closureTabDepth`	10 mm	5–20 mm	Length of the locking tab from its crease; at least two material thicknesses so it reaches through the front wall and holds behind it.

Assembly

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

Grain direction

Flute direction parallel to the blank's y-axis: The double-wall creases fold neatly, while lid hinge and tuck flap stay stiff (check with a test print shop).

Reference note

similar to FEFCO 0426 · classification unconfirmed

Labels such as “similar to FEFCO” or “ECMA family, unconfirmed” are for orientation only. The templates are our own constructions; an assignment to a standard code is unconfirmed and not a trademark claim.

Frequently asked questions about this template

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 defined in the source code erects front and back walls, folds in the ears, and locks the side walls into the bottom. The lid closure then engages through the front wall. No gluing is intended for this structure. Whether additional transit securing is necessary depends on the shipping process and is not confirmed by calculation.

Why can't the closure flap 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 changes to height and closure together.

How many lid tabs can I choose?

The parameter range offers one to three locking tabs, with two as the starting value. The available area also limits their width. An additional tab therefore does not provide independent reinforcement. The fitsClosure constraint checks count and width together; you must determine actual holding force on a sample.

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