Packaging & Box Dielines

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.

The ECMA A20.20.03.01 Reverse Tuck End (RTE) and Straight Tuck End (STE) folding carton is the universal paperboard packaging structure used for cosmetics, dropper bottles, pharmaceuticals, playing cards, and retail consumer goods. Constructed from four alternating body panels (L, W, L, W) joined by a 15-degree tapered side glue flap, the carton closes at the top and bottom via hinged tuck flaps flanked by notched dust flaps. Our parametric generator calculates exact dust-flap shoulder relief notches (1.5T) and friction-lock tuck ears so the lid closes flush without springing open on retail shelves.

A paper coffee cup is not a cylinder—it is a truncated mathematical cone (frustum). If you wrap a flat rectangular strip around a tapered cup, it gaps at the bottom and slips off. To sit flush against the cup wall, a coffee cup sleeve must be unfolded radially as an annular sector computed from the cup's Top Diameter (D_top), Bottom Diameter (D_bottom), and Vertical Sleeve Height (H). Our parametric generator solves the exact cone apex radii (R_outer and R_inner) and sector angle (theta) to generate a 1:1 curved dieline with an interlocking tab-and-slot closure or glue lap.

The Pillow Box (ECMA F10.10) is an elegant, self-tensioning curved packaging structure that pops into a 3D pillow shape when its four parabolic end flaps are folded inward along curved score lines. The mathematical secret of a functional pillow box is that the inner crease arc and the outer cut arc of each end flap MUST share the exact same circular radius (R_arc) mirrored across the chord line; otherwise, the flap buckles or leaves gaps. Our parametric engine computes the exact sagittal chord radius from your desired Body Length (L), Flat Width (W), and Gusset Loft Depth (H).

An ECMA A55.20 Gable Top Handle Box combines a four-panel folding carton body with a pitched triangular gable roof, integrated die-cut carry handle collar, and interlocking bottom flaps. In commercial bakery, foodservice, and gift packaging, the side gusset triangles must fold inward along 45-degree diagonal score lines while the front and back roof panels meet at a double-ply ridge lock. Our parametric dieline generator automatically computes the gable pitch height (0.52 × W), ergonomic handle cutouts, and board thickness relief offsets (1.5 × T) in 1:1 vector .DXF, .SVG, and .PDF.

The FEFCO 0201 Regular Slotted Container (RSC) is the world's most widely manufactured corrugated shipping carton, accounting for over 75% of global logistics and fulfillment boxes. Its flat blank consists of four contiguous body panels (L, W, L, W) joined by a tapered manufacturer's glue joint tab, with top and bottom flaps of equal depth (H_flap = 0.50 × W) separated by vertical die-cut relief slots (W_slot = max(4mm, 2 × T)). When the outer lengthwise flaps fold inward, they meet cleanly at the center seam for H-taping.

Retail Point-of-Sale (POS) countertop displays and Costco/Walmart PDQ (Pretty Darn Quick) shelf-ready trays require a low front lip so shoppers can see the product label, angled side walls for peripheral visibility, and a tall rear billboard header for brand graphics. Our parametric FEFCO 0422 PDQ display generator unfolds a single-piece corrugated blank featuring a base floor (`L × W`), a tall rear backboard (`H`) with an integral top billboard header flap, a low front shopper lip (`28% of H`) with a rollover reinforcement lock, and two tapered triangular side walls with rear glue/lock flaps.

The ECMA A60.20 / FEFCO 0216 Snap-Lock Bottom (commonly called a 1-2-3 Bottom Folding Carton) is the premier heavy-duty retail box structure engineered for glass candle jars, ceramic coffee mugs, beverage bottles, and heavy cosmetics that would push open a standard tuck-end bottom. Its base consists of four interlocking flaps—a slotted anchor flap, two side hook flaps, and a male locking tongue—that snap together sequentially (1-2-3) to form a high-capacity load-bearing floor without bottom glue.

The Two-Piece Sliding Drawer Tray and Outer Sleeve Box (Matchbox style / FEFCO 0501) is one of the most popular luxury unboxing structures for cosmetics, chocolates, jewelry, tech gadgets, and gift cards. Unlike single-piece cartons, a tray-and-sleeve box requires two precision-mated blanks: an inner four-wall tray (L × W × H) and an outer tubular wrap sleeve whose internal width and height are automatically expanded by a calibrated sliding clearance (+1.2mm to +2.5mm depending on board thickness T) so the drawer glides smoothly without binding or falling out.

The Beverage Bottle Carrier Basket is the industry-standard retail multipack structure for craft beer bottles (330ml/12oz and 500ml), cold-pressed juice bottles, hot sauce sets, and coffee shop takeaway cups. Engineered from high-wet-strength CUK (Coated Unbleached Kraft) or E-flute corrugated board, it combines a perimeter tray basket, central vertical riser panels with reinforced ergonomic die-cut hand grip slots, and interlocking bottom flaps.

The Gusseted Retail Paper Shopping Bag dieline is the universal flat-sheet pattern used for luxury boutique bags, gift bags, apparel carriers, and restaurant takeaway bags. Constructed from a single wrap-around sheet (or two sheets for extra-wide bags), it features front and back display faces (L), pleated side gussets (W) with center valley creases, a 35mm top reinforcing turnover cuff with four Ø6mm rope/ribbon handle eyelets, and a diamond-creased block bottom that folds flat for storage.

The FEFCO 0320 Two-Piece Telescopic Lid and Base Box (also known as a Setup Box, Shoe Box, or Board Game Box) consists of a lower base tray and a slightly wider upper lid that telescopes smoothly over the base. Whether cut from chipboard/greyboard for luxury rigid boxes or folded from cardstock/corrugated board, the critical engineering requirement is the Telescopic Lid Clearance: the lid's internal length and width must exceed the base by +2T (plus wrap paper allowance) so the lid slides on with a slow air-cushioned release.

The Rigid Book Mailer & Variable-Capacity Envelope Folder (FEFCO 0401 / One-Piece Wrap Mailer) is the preferred flat-pack shipping packaging for hardcover books, vinyl LP records, art prints, catalogs, and flat electronics. Constructed as a cruciform (cross-shaped) blank, the product is placed in the center panel, the left and right wings fold inward over the edges, and the bottom and top panels wrap around and seal with a hot-melt peel-and-seal strip and an integrated perforated zipper tear-strip for frustration-free opening.