FEFCO 0427 / Die-Cut Roll-End Tuck Top (RETT) 1:1 DXF · SVG · PDF Default Spec: 220 × 160 × 75 mm (T=1.5mm)

FEFCO 0427 E-Commerce Mailer Box Dieline Generator

1:1 CAD ENGINE READY

FEFCO 0427 E-Commerce Mailer Box Dieline Generator

1CAD Style & Material SetupPackaging

Select CAD Style / Model (36)Search & Filter

Material Stock Preset (Auto-Sets Caliper T & Kerf K)

Display Units

Reference Mode

2Dimensions (ID Mode)Millimeters (mm)

Internal Length (L)220 mm

Internal Width (W)160 mm

Internal Height / Flange (H)75 mm

Inside ID: 220×160×75mmOutside OD: 223×163×78mm

Thickness (T mm)

Laser Kerf (K mm)

3Brand Logo & 1:1 ExportZero Login

2D & 3D Brand Logo Mockup:

📤 Upload Logo

Print Artwork Bleed Guide:

Embed Spec Sheet & 50mm / 1" Scale Bars (Added on separate DIMENSIONS layer)

Pre-Flight Geometry Audit8/8 PASSED

PASS
Closed Outer Contours: 3 closed LWPOLYLINE cut loop(s) verified
PASS
Zero Duplicate Cut Paths: 42 unique segments (0 laser double-burns)
PASS
Flute & Kerf Tolerance Guard: T=1.50mm, K=0.000mm within structural limits
PASS
ISO Layer Color Separation: CUT (Red), CREASE (Blue), SCORE (Emerald), DIMENSIONS isolated
PASS
1:1 Physical Unit Header: Explicit mm/in SVG viewBox + DXF $INSUNITS=4 + 50mm PDF bar
PASS
Exact 2D Cut Bounding Parity: Cut Bounds 522.5×512mm === Blank Size
PASS
2D ↔ 3D Kinematic Model Sync: Archetype 'mailer_0427' synced (6 3D component(s))
PASS
True Vector Sheet Nesting Sync: 1:1 vector paths mapped to multi-up sheet grid

100%

CUT (3.06m) CREASE/SCORE (2.51m)● 3 Loops · Est. Cut: ~104s

1:1 Synced · Blank: 522.5 × 512 mm

2D 1:1 Unfolded Vector BlueprintBlank: 522.5 × 512 mm (20.57" × 20.16")

3D Interactive Fold & Orbit (Kraft Board)

80%

0%100%

Camera:

Yaw: -28°Pitch: 24°

⟳ Drag Anywhere to Rotate 3DL=220 × W=160 × H=75mm

BASE (220×160mm)

FRONT (H=75)

REAR WALL

TOP LID (80%)

TUCK FLAP + EAR LOCKS

Flat Blank Size

522.5 × 512.0 mm

Rollover Bridge (2T)

3.50 mm

Sheet Area

0.268 m²

FEFCO Standard

FEFCO 0427 (RETT)

Structural & Manufacturing Specification Summary

Quick Default Download: ↓ .DXF ↓ .SVG ↓ .PDF

The FEFCO 0427 (Roll-End Tuck Top / RETT) mailer box is the global industry standard self-locking corrugated packaging design for e-commerce subscriptions, retail kits, and D2C shipping. Engineered from a single die-cut sheet without glue or tape, it features double-layered side walls that fold over integrated dust flaps and lock into precision bottom slots, while the hinged top lid secures via dual front friction-lock ears. Our parametric engine automatically compensates for corrugated board thickness (T) across E-flute (1.5mm) and B-flute (3.0mm) by widening rollover bridges by 2T and setting dust flaps back by 1.5T to prevent fiber crushing.

CUT LAYER #EF4444 (ACI 1)

CREASE / BEND #2563EB (ACI 5)

SCALE HEADER $INSUNITS=4 (1:1 mm)

SIMULATION 2D + 3D + Nesting

Pre-Calibrated Industry Sizes (2)

Standard Product Presets Built on This FEFCO 0427 Mailer Box Engine

152 × 102 × 51 mm (T=1.5mm)

6x4x2" Small Mailer Box

152.4 mm x 101.6 mm x 50.8 mm (6" x 4" x 2" USPS First-Class / Royal Mail Small Parcel Tier)

Load Preset Spec →

310 × 310 × 45 mm (T=2mm)

12-Inch Corrugated Pizza Box

Fits Standard 12-Inch (305 mm) Pizza Pie with 5.0 mm Steam & Crust Clearance

Load Preset Spec →

Structural Geometry & Allowances

Mathematical Blank & Tolerance Formulas

Total Flat Blank Width (W_blank)

W_blank = L + 2(H) + 2(2T + H_rollover) + 2(W_lock_ear)

Accounts for interior length (L), two vertical side walls (H), two double-wall rollover bridges (2T), and two inner locking wall panels.

Total Flat Blank Length (L_blank)

L_blank = H_back + W_base + H_front + W_lid + H_tuck_flap + 3.5T

Sums the rear wall, bottom base, front double wall, top lid panel, front tuck-in flap, and cumulative 90-degree flute crease allowances.

Rollover Bridge Allowance (Delta_bridge)

Delta_bridge = 2 * T + 0.5 mm

Essential double-crease spacing that wraps over both the vertical side wall and the tucked dust flap without buckling.

Pre-Press & Production SOP

Step-by-Step Export & Assembly Guide

1 Enter your product's exact Internal Dimensions (Length x Width x Height) plus at least 2mm clearance per axis, and select your corrugated board thickness (T).
2 Inspect the live 2D CAD Blueprint and drag the 3D Folding Simulator slider from 0% to 100% to verify dust flap and rollover wall clearances.
3 Click Export 1:1 Vector File (.DXF for AutoCAD/Kongsberg/Laser, .SVG or .PDF for Adobe Illustrator artwork placement).
4 In Adobe Illustrator or CAD software, keep the RED layer ('CUT') assigned to through-cutting knives/laser and the BLUE dashed layer ('CREASE') assigned to creasing rules.
5 Fold the front and rear walls up 90 degrees, fold the side dust flaps inward, wrap the double side walls over the dust flaps until the bottom tabs snap into the base locking slots, and close the top lid ears.

Board Caliper, Laser & Die-Cutting Reference

Material Thickness, Creasing Matrix & Laser Kerf Settings

Material / Sheet Stock	Caliper Thickness (T)	Recommended Tooling / Laser Setup	Allowance / Kerf Spec	Primary Use Case
Micro-Flute Corrugated (E-Flute)	1.5 mm (1/16 in)	2pt Creasing Rule (0.71mm) + 1.5x4.0mm Matrix	Crease Offset: 1.5mm / Bridge: 3.5mm	Cosmetics, apparel boxes, subscription mailers under 2.5 kg
Fine Corrugated (F-Flute)	0.8 mm (1/32 in)	2pt Creasing Rule + 1.0x3.0mm Matrix	Crease Offset: 0.8mm / Bridge: 2.0mm	Luxury retail electronics, perfume sets, small gift mailers
Standard Corrugated (B-Flute)	3.0 mm (1/8 in)	3pt Creasing Rule (1.05mm) + 3.0x7.0mm Matrix	Crease Offset: 3.0mm / Bridge: 6.5mm	Heavy shipping mailers, shoe boxes, ceramic & glassware transit
Heavy Folding Boxboard (SBS / Kraft 450gsm)	0.6 mm	1.5pt Creasing Rule + 0.6x2.2mm Matrix	Crease Offset: 0.5mm / Bridge: 1.5mm	Lightweight retail counter mailers and document presentation boxes

Packaging & CNC Engineering FAQ

Frequently Asked Questions — FEFCO 0427 Mailer Box

Why does my mailer box bulge at the sides if I don't set board thickness (T)?

In a FEFCO 0427 mailer box, the side walls fold 180 degrees over the internal dust flaps. If the rollover bridge equals zero instead of 2T + 0.5mm, the outer wall crushes the inner dust flap and forces the side panels to bow outward.

Are the dimensions entered in this FEFCO 0427 generator Inside Dimensions (ID) or Outside Dimensions (OD)?

All dimensions (L x W x H) entered into CadFold packaging generators represent strict Inside Dimensions (ID)—the usable internal cavity available for your product. Outer dimensions are automatically expanded by the board thickness formula.

How do I open the exported SVG or PDF in Adobe Illustrator at exact 1:1 millimeter scale?

Our SVG and PDF files embed explicit physical millimeter units (mm) in the root header rather than screen pixels. Simply use File > Open in Adobe Illustrator (do not drag-and-drop onto a scaled artboard) and verify the 50mm calibration scale bar at the bottom.

Can I cut an E-flute corrugated mailer box prototype on a CO2 or Diode laser cutter?

Yes. Export the .DXF or .SVG file with 'Include Dimensions Layer' unchecked. Assign the RED (CUT) layer to 100% through-cut power (e.g., 45mm/s at 35% power on a 60W CO2 laser) and the BLUE (CREASE) layer to a light surface score or dashed perforation (120mm/s at 12% power).

Topical Silo Navigation (Packaging Dielines)