Die-cut postal boxes
Tape-free constructions that lock closed, pack quickly by hand and arrive looking deliberate rather than improvised.
FEFCO 0427Capability
E-commerce and postal packaging.
Die-cut mailers, postal boxes, subscription packs and protective fittings, right-sized for carrier charges and built to survive the parcel network. Specified by RightBox and supplied through the partner sites set up for die-cut work.
Formats
What this covers.
Each format solves a different problem. The right one depends on the product, the route it takes and what happens at the other end.
Slim mailers & wraps
Low-profile formats for flat products, built to stay within letterbox and carrier size bands.
FEFCO 0471Five-panel wraps
Wrap-around constructions for long or awkward items that do not suit a square box.
FEFCO 0409Subscription packs
Repeat-shipment formats with consistent print, designed around a recurring unboxing experience.
Retail-readyInserts & fittings
Die-cut fittings that hold products apart and stop movement, which is what prevents most transit damage.
FEFCO 0426Returns-friendly formats
Tear strips and resealable closures, so a return goes back in the same box it arrived in.
Discuss returnsSpecification
What decides the construction.
Dimensional weight
Carriers charge on size as well as weight. Taking 20mm out of a box can move it into a cheaper band across every parcel you send.
Damage rate
Parcel networks are harsher than palletised delivery. Board grade and internal fittings are what bring returns down.
Packing speed
A mailer that erects in one movement costs less to pack than one that needs tape and a second pair of hands.
Void space
Every millimetre of air is paid for twice: once in freight, once in void fill.
Presentation
For many brands the delivery is the only physical contact with the customer, which is where print and finish earn their cost.
Returns journey
If the product comes back, the pack has to survive a second trip or the customer needs another one.
How it is supplied
Specified once, shipped consistently.
- Right-sizing reviews across a product range, not box by box
- Die-cut tooling specified and stored against each size
- Board grades matched to the carrier and the journey, not inherited from the previous supplier
- Print and finish specified where presentation matters, kept plain where it does not
- Call-off arrangements so peak periods do not run you out of stock
- Placed with partner sites equipped for die-cut and short-run digital work
Questions
Common questions.
How do I reduce carrier costs on packaging?
Start with dimensions. Most carriers charge on volumetric weight, so reducing box size moves parcels into cheaper bands. The Pallet Calculator and Box Finder will help you test alternatives before you commit to new tooling.
What is the difference between a postal box and a mailer?
In practice the terms overlap. A postal box such as FEFCO 0427 is a die-cut box with an integral lid that locks closed without tape. A mailer is usually slimmer, for flat products. Both are die-cut and both need tooling.
Do die-cut boxes need tooling for every size?
Yes, each size needs its own cutting die. That is why rationalising a range of sizes down to a core set usually saves more than negotiating on price.
Can you print inside the box?
Yes. Inside print is common on subscription and premium e-commerce packs, and it costs less than most people expect when specified at the same time as the outside.
Does RightBox manufacture the packaging?
No. RightBox specifies and manages supply through 43 partner manufacturing sites, placing each requirement with the site equipped for it.
Next step
Send us your current mailer range.
Tell us the sizes you buy today and the carriers you use. We will show you where the range can be rationalised and where dimensional weight is costing you money.