A box template from the inside size
Type the space you need inside the box and the card you have. The dieline adds the card thickness at every fold, so the folded box really is that size inside. The mailer locks with tabs through slots in the floor – no glue, no tape – and its corner ears are trapped inside the rolled side walls, which makes it surprisingly strong.
From dieline to box
- Pick a style and type the inside length, width and height.
- Measure your card with calipers and type the thickness. Presets are only a starting point.
- Check the Folding and Closed views: every flap should land where you expect.
- Download the SVG or DXF for a laser cutter (cut red, score blue), or the PDF to print and cut by hand.
- Cut one test box from scrap, fold it along the blue lines and check the fit before cutting good card.
Frequently asked questions
Are the sizes inside or outside?
Inside. Length, width and height are the space you get inside the folded box. The dieline adds the card thickness at every fold (more for the rolled double walls of the mailer), so measure your card and type its real thickness.
Which box style should I use?
Mailer (FEFCO 0427 style): a sturdy box that locks with tabs and needs no glue or tape – good for shipping small items. Tuck-end: a retail-style carton with one glued seam and friction-lock tuck flaps. Shipping carton (0201 RSC): the standard brown box, closed with tape. Pizza / cake: the same no-glue 0427 build, wide and shallow. Two-piece: a base tray and a lid that slides over it. Drawer box: a tray that slides into a sleeve, with thumb notches - nice for gifts. Snap-lock bottom: a tuck-top carton whose bottom locks with no glue or tape - quick to pack. Open tray: a simple tray with glued corners. Sleeve: an open-ended band that slides over a box or product.
What do the colours mean?
Red is the CUT layer: the outline, the slots for the locking tabs and short slits between flaps. Blue is the SCORE layer: every fold line. In your laser software, cut red through and score blue lightly (low power or fast speed) so the card folds cleanly without breaking. If your laser can only cut, choose "Perforated folds": the blue lines become real dashes you cut through.
What is kerf and should I change it?
Kerf is the width of card the laser burns away. The cut outline is moved out by half of it so the box comes out at its true size. 0.1 mm suits most diode and CO₂ lasers; for hand cutting from the PDF, set it to 0.
What card can I cut it from?
Any: a sheet of any size, a cardboard roll, or reclaimed packaging such as a flattened filament box. Turn on "Check it fits my card" and pick the stock. For a sheet, the preview shows the blank on it (turned if that helps) and "Find the largest mailer" picks the biggest mailer that fits at your height. For a roll only the width matters: it tells you how much roll the box uses.
How do I print the PDF at the right size?
The PDF is full size on one page by default, for a large-format printer, plotter or print shop. If you only have a home printer, choose tiled A4, A3 or US Letter: the dieline is split over sheets that overlap by 10 mm, with crosses to line them up. Always print at 100 % / actual size, never "fit to page", and measure the 100 mm check bar.
Is this a certified FEFCO die?
No. The mailer and shipping carton follow the common FEFCO 0427 and 0201 layouts, but they are practical patterns, not manufacturing dies. Always cut one test box from scrap and check the fit and the locks before cutting good card.