Ultimate Guide to Roll End Tuck Top (RETT) Mailer Boxes

When shipping products directly to consumers, the mailer box is the first physical touchpoint for your brand. It must not only look professional but also protect the contents from rough transit.

For many e-commerce brands, the Roll End Tuck Top (RETT) mailer box is the go-to solution. Combining double-wall crush safety with a clean, tape-free assembly, it represents the ideal packaging container.

In this guide, we break down RETT design, board flute thickness, and printing customizations.

1. What is an RETT Box?

The Roll End Tuck Top (RETT) box is a single sheet of die-cut corrugated board. During assembly, the side flaps roll over into the bottom panel, locking into pre-cut slots. This creates double-layered sidewalls on the left and right.

The top lid folds forward, featuring side dust flaps that tuck inside the box to block debris, and a tuck tab that locks into the front panel.

2. Choosing Your Corrugated Board Thickness (Flutes)

Corrugated board is categorized by the thickness of its wavy flutes:

E-Flute (1.6mm thickness)

The industry standard for e-commerce. Thin flutes provide a flat, smooth printing surface and excellent folding capability.

B-Flute (3.2mm thickness)

Thicker flutes. Recommended for shipping heavy items (shoes, glass jars, bulk metals) that need extra cushion and burst safety.

F-Flute (0.8mm thickness)

Micro-flute board. Offers a highly compact, paperboard-like look while maintaining corrugated crush safety.

3. Optimizing the Unboxing Experience

The unboxing experience is a powerful marketing tool. Rather than leaving the inside of your box blank, printing a colorful pattern or a "Thank You" message inside the lid engages customers immediately.

Custom Inserts

For delicate products, adding a custom-cut cardboard insert holds jars or dropper bottles securely, ensuring they do not shake or break during shipping.

Frequently Asked Questions

Do RETT boxes require glue or tape?

No. The interlocking tabs fold and lock mechanically. The lid tucks securely into the front panel, holding the box closed without requiring adhesive.

What is the difference between RETT and RETF?

RETT (Tuck Top) boxes tuck into the top from the back, leaving a clean front display. RETF (Tuck Front) boxes feature locking tabs that slide into the front wall, which offers slightly higher security for heavy shipping.

Source Custom RETT Mailers Today

Explore our category of custom mailer boxes, or request a dieline template to start designing your artwork.