Do you have a guide for Assembling Mailer Boxes?

Assembling a mailer box might seem a bit daunting, but with the right approach, it can be a smooth and straightforward process. Follow these steps to assemble your mailer box correctly, check out our tips to make the whole process easier, and avoid the common mistakes people usually make when assembling a mailer box.  

 

Step 1: Tidy up your workspace. 

Clear out off a clean, flat work surface that is larger than your un–assembled box sheet. This prevents any damage to the box or its creases.  

Ensure the surface is free from clutter, ensuring,  a distraction-free and organized environment. 

Step 2: Crease the scores. 

Look for the pre-fold lines (scores) on the interior side of the unassembled box sheet. Fold each score towards the interior to create well-defined creases. 

Pay extra attention to the two scores on the sidewall that are close to each other. Fold each crease separately to ensure the sidewall fits properly. 

Step 3: Fold the front and back flaps. 

Fold the front and back flaps forward while keeping the tuck flaps on the sides as much as possible.  

Gently brace the back flap in place to ensure stability as you proceed to the next step. 

Step 4: Bring up the side walls. 

Fold the left and right-side flaps over the tuck flaps to bring up the side walls. 

Simultaneously snap the side walls into place, ensuring symmetry and evenness. This results in a snug fit and secure structure. 

Check that the tops of the side walls are flat and not slanted or peaked. 

Step 5: Lock the box. 

Now that your box structure is formed, place adds your contents inside the box. 

Close the lid and slide the locking tabs into their designated slots in the sidewall. Now you have a sturdy and locked mailer box! 

 

A Few Tips for Smoother Mailer Box Assembly

• Opt for a custom mailer box tailored to your product’s size or dimensions if possible. This can streamline the assembly process. 
• If your mailer box has instructions, follow them carefully to avoid mistakes. 
• A box cutter can expedite the cutting and folding and save you time and effort. 

 

Common Mistakes When Assembling a Mailer Box

• Failure to fold along the pre-fold lines can lead to an improperly assembled box. 
• While mailer boxes may not require glue, securing flaps with tape is crucial to prevent accidental openings during transit. 
• Assembling on a cluttered or uneven surface can result in errors and damage to the box.

 

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