Mailing boxes are the workhorse of Australian eCommerce. They're light, strong, look far more professional than a satchel and protect products that need more than a bag.
But open any packaging catalogue and you'll see several styles: diecut mailers, tuck front boxes, self-seal boxes and regular shipping cartons. They can look similar in photos, yet they pack, seal and open quite differently.
This guide explains each style, its pros and cons, and how to choose the right mailing box for your products.
Mailing Box Styles at a Glance
| Diecut mailing box | Premium tuck mailing box | Self-seal mailing box | Regular shipping carton (RSC) | |
|---|---|---|---|---|
| How it closes | Lid folds over and tucks in, often taped | Lid tucks into front, no tape needed | Peel-and-stick adhesive strip | Four top flaps, taped |
| Packing speed | Fast | Fast | Fastest | Slower |
| Presentation | Good | Excellent | Very good | Basic |
| Tamper evidence | With tape | With tape or a seal sticker | Built in | With tape |
| Best for | Everyday eCommerce orders | Gifts, premium and subscription products | High-volume dispatch | Larger, heavier or bulk shipments |
Diecut Mailing Boxes
"Diecut" describes how the box is made: it's cut and creased from a single sheet of corrugated board using a custom cutting die. The flat sheet folds into a box with a built-in lid, side walls and dust flaps, usually without glue.
Why businesses choose them
- Sturdy double-thickness side walls when folded
- Arrive flat, so they take up little storage space
- Quick to fold once your team has done a few
- Huge range of sizes, from tiny jewellery boxes to A4 and beyond
- Available in brown, white, black and a range of colours
Things to consider
- Most people add a strip of tape or a sticker to secure the lid for courier handling
Best for: the majority of everyday eCommerce orders, including clothing, accessories, cosmetics, books and homewares.
Browse diecut mailing boxes, including white, brown, black and pink.
Premium Tuck Mailing Boxes
Tuck front (or tuck top) mailing boxes have a lid with a front flap that slides neatly into the front of the box. Many also have "ears" on the lid that lock into the side walls, so the box stays closed firmly without tape.
Why businesses choose them
- A clean, retail-quality look with no tape on the presentation surface
- A satisfying opening experience, ideal for gifts and unboxing videos
- Can be reopened and closed again, so customers can keep and reuse them
- Popular in full black and colour finishes for a premium feel
Things to consider
- Because they open easily, add a seal sticker or tape if you want tamper evidence
- Usually cost a little more than standard diecut boxes
Best for: gifts, subscription boxes, cosmetics and skincare, jewellery, candles and any brand that wants a premium presentation.
Popular sizes include the A5 premium tuck black box (220 x 160 x 77mm) and the A4 premium tuck black box (310 x 230 x 105mm). See all premium tuck mailing boxes.
Self-Seal Mailing Boxes
Self-seal mailing boxes have a strip of adhesive on the lid protected by a peel-off liner. Fold the box, pack it, peel the strip and press it closed. No tape gun required.
Why businesses choose them
- The fastest box to pack and seal, which adds up when you're sending hundreds of orders
- A clean finish with no tape
- Tamper-evident: once sealed, it can't be opened without visible damage
- Consistent seal quality, whoever is packing
Things to consider
- Once sealed, they can't be reclosed without tape, which matters if customers might return items
- Adhesive works best when boxes are stored in a cool, dry place
Best for: busy fulfilment operations, high-value goods where tamper evidence matters, and businesses that want to remove tape from the packing bench.
Sizes include the A5 self-seal box (220 x 160 x 77mm), A4 self-seal box (310 x 230 x 105mm) and 270 x 160 x 120mm. See all self-seal mailing boxes.
What About Regular Shipping Cartons?
Regular slotted cartons (RSCs) are the classic brown box with four flaps on top and bottom. They're the most economical choice for larger and heavier items, bulk orders and warehouse shipments, but they need taping top and bottom and don't offer the same presentation as a mailer box. Learn more in our guide to regular slotted cartons, or browse medium and large boxes.
How to Choose the Right Mailing Box
Ask yourself these questions:
1. How many orders do you pack each day?
If it's a handful, any style works. If it's hundreds, self-seal boxes can save a surprising amount of packing time.
2. How important is the unboxing experience?
For gifts, premium products and social-media-friendly brands, a premium tuck box in black or colour makes a strong first impression. Our guide to creating an unboxing experience on a budget has more ideas.
3. Do you need tamper evidence?
For electronics, supplements or high-value items, self-seal boxes give built-in tamper evidence.
4. How heavy or fragile are your products?
Standard mailing boxes suit most light to medium items. For heavier products, consider heavy duty mailing boxes (see when to use heavy duty boxes).
5. Will customers return items?
Tuck boxes and diecut boxes are easy to reuse for returns. Self-seal boxes will need tape.
6. What size do you need?
Measure your product and allow for any protective packaging. Our guide on how to measure a box explains internal and external dimensions, and our AusPost prepaid satchel box size guide shows which boxes fit inside prepaid satchels.
Try Before You Buy in Bulk
The best way to choose is to test a few styles with your actual products. Order a small pack of two or three styles, pack some real orders and see which works best for your team and your customers.
Browse the full range of mailing boxes and shipping cartons at eBPak, or if you'd like your logo on your boxes, read our guide to custom printed boxes.