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An ear lock mailer box is a corrugated mailer whose side flaps lock into die-cut ears rather than tucking, so the box closes without tape and stays closed when it is picked up, dropped or squeezed. The lid folds over the front and two small tabs, the ears, slot into the side walls. We make them in E and B flute, printed inside and out, in any size and with no minimum order. The number that matters is packed weight: an ear lock holds a lid shut under more load than a plain tuck front, which is why it is the mailer for heavier contents and for orders that get handled more than once, up to about 8 pounds in B flute.
The difference from a roll end tuck front mailer is small to look at and large in use. A tuck front lid can pop open when a heavy box is dropped on its face; the ears keep the lid locked in. For subscription boxes over 3 pounds, for glass, for anything that opens and closes several times before it is thrown away, the ear lock is the structure to choose.
Sizes
Ear lock mailers are sized as inside length by width by depth. Depth is the dimension the ears are built into, so it is usually 2 to 6 inches; wider or deeper than that and the ears stop holding well.
| Size (inside) | Holds | Board |
|---|---|---|
| 9 x 6 x 2 in | books, apparel, cards, flat goods | E flute, 32 ECT |
| 10 x 8 x 3 in | subscription sets, cosmetics, small electronics | E flute, 32 ECT |
| 12 x 9 x 4 in | apparel bundles, gift sets, food boxes | B flute, 32 ECT |
| 12 x 12 x 4 in | vinyl records with mailer inserts, framed prints | B flute, 32 or 44 ECT |
| 14 x 10 x 6 in | heavy sets, glassware with inserts, kits | B flute, 44 ECT |
Ear lock, tuck front or auto bottom
| Structure | Closes by | Holds shut under | Best for |
|---|---|---|---|
| Roll end tuck front | front flap tucks under the lid | light contents, single open | subscription boxes under 3 lb, apparel, print |
| Ear lock | two tabs lock into the side walls | heavier contents, repeated open and close | boxes 3 to 8 lb, glass, records, sets that get reopened |
| Roll end with auto bottom | base is pre-glued and springs open | fast packing | high volume lines where seconds per box count |
Board
E flute, about 1/16 inch, for boxes under 3 pounds; it prints the finest detail. B flute, about 1/8 inch, from 3 pounds up, because it takes a drop and the ears hold better in a thicker wall. 32 ECT is the standard grade; 44 ECT for boxes over 6 pounds or long transit legs. Tell us the packed weight and we will confirm the grade on the quote.
Print and inserts
Full color inside and out, so the lid opens on a printed panel. Matte aqueous coating resists scuffs in the parcel network. A die-cut insert holds glass or a record still; a paperboard divider separates a set. The ears and the lid line are marked on the dieline so artwork does not land on a fold.
In short
What to send us: the contents and packed weight, the inside size you need, how many times the box is opened, and how many you need. What you get back: an ear lock or tuck front recommendation with the reason, a size, the board for the weight, a dieline with the ears marked, and a physical sample to load and drop. What it costs you to start: nothing. Free design, free dieline, free samples, no minimum order.
Ear lock mailer questions
What is an ear lock mailer box?
A corrugated mailer whose lid locks shut with two small tabs, the ears, that slot into the side walls, instead of a front flap that tucks. It closes without tape and stays closed when dropped or squeezed. Used for heavier contents and boxes that are opened more than once.
Ear lock or roll end tuck front?
Tuck front for light contents and a single opening: subscription boxes under 3 pounds, apparel, print. Ear lock for 3 to 8 pounds, glass, records, and anything reopened several times, because the ears hold the lid shut under load.
How much weight does an ear lock mailer hold?
Up to about 8 pounds in B flute at 44 ECT with the contents held by an insert. E flute at 32 ECT covers boxes to 3 pounds. The board, not the lock, sets the limit; tell us the packed weight and we will confirm the grade.
Do ear lock mailers ship flat?
Yes. They ship flat in bundles and fold up by hand in a few seconds: base flaps, side walls, lid over, ears into the slots. No tape.
Is there a minimum order?
No. A hundred to test or a production run. Free design and dieline, free samples to load and drop, and a printed proof before the run.
No minimum order. One or a full run. Free design and dieline, and a printed proof before production. Free samples so you can load one, drop it, and reopen it before you commit. Price match: send a written quote for the same size, board, print and quantity and we will beat it.
Related: vinyl record mailers, custom mailer boxes, luxury mailer boxes and all mailer boxes.
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