Overview & Specifications
What Is a Roll End Box with Lid?
A roll end box with lid is a two-part folding mailer: a base whose walls roll over into a double layer of board, and a separate lid formed the same way and sized slightly larger, so it slides down over the base. Removing the lid exposes the entire packed arrangement at once, a shoebox-style opening, while both parts stay foldable board rather than rigid setup board.
How the Lid and Base Fit Together
The format works through two parts folded from separate blanks.
01
Roll-End Base
The base walls fold over and lock into the floor, forming a double-layer perimeter that the lid slides down over.
02
Separate Lid
The lid folds up from its own blank, with walls sized to clear the outside of the base. Its depth sets how much of the base it covers.
03
Lid Overlap and Fit
How snugly the lid sits depends on board caliper or flute, dimensions, overlap depth and tolerance. Fit is set on the dieline and confirmed on a sample rather than promised as friction-tight.
Anatomy of a Roll End Box with Lid
01
Lid
Separate top with its own walls; the main print surface when closed.
02
Lid Walls
Set how far the lid drops over the base.
03
Base
Holds the product; rolled walls form the outer surface the lid covers.
04
Rolled Walls
Double-layer base perimeter.
05
Insert
Optional insert, divider or cushioning inside the base.
With a short lid, part of the base wall shows when closed, so print the visible band as part of the design. Lid and base are printed as separate blanks, so colors are matched across both.
Lid Depth Options
Lid depth is the main styling decision on this structure.
| Lid Style | How It Sits | Typically Suited To |
|---|---|---|
| Full-depth lid | Lid walls reach the bottom of the base | Closed, carton-like look; stacking and storage |
| Partial lid | Lid covers part of the base, leaving a printed base band | Two-tone or contrast branding |
| Shallow lid | Short lid over a deeper base | Gift sets and kits where the base carries the design |
Application guide
When Is a Roll End Box with Lid the Right Choice?
A roll end box with lid suits shipments where the whole arrangement should be seen at once, such as apparel and footwear-style presentation, subscription and gift sets, lifestyle goods and promotional kits, while keeping the cost and flat storage of a folding mailer.
01
Full-Lid
Full-Lid Reveal
Lifting the lid shows every item at once, which suits kits, folded garments and curated sets.02
Two
Two Printable Parts
Lid and base can carry matching or contrasting graphics, so the box reads as a designed object rather than a carton.03
Easy
Easy Re-Use
A lift-off lid is simple to put back on, so customers keep the box for storage.04
Alternative
When Another Format May Fit Better
If the packing team needs one piece per order, choose an attached-lid mailer such as the Roll End Tuck Top Box or the Roll End Tuck Front Box, or the Roll End 3 Flap Lock Box for an interlocking close. For a rigid keepsake box with a lift-off lid, see the Custom Two Piece Box.
Roll End Box with Lid Specifications
Custom roll end boxes with lid are specified around lid depth and overlap, the roll-end base, board and flute, inserts and sealing, with the lid and base cut from matching dielines so the lid fit is planned rather than left to tolerance.
| Specification | Available Configuration |
|---|---|
| Product Type | Roll-end mailer base with separate removable lid |
| Category | Mailer Boxes |
| Dimensions | Custom inside L × W × D, built around the product, insert and lid overlap |
| Core Construction | Two die-cut blanks: rolled-wall base + separate lid |
| Closure | Lid-over-base fit; tape, label or band where shipping requires |
| Lid Depth | Full-depth, partial or shallow lid |
| Board | Corrugated (E-flute, B-flute or other flute by project), white SBS, kraft or recycled paperboard; metallic, holographic, pearlescent or textured cardstock |
| Board Thickness (quote form) | Paperboard (18–24 pt), E-flute corrugated, B-flute corrugated, or not sure, advise me |
| Inserts | Paperboard, corrugated, foam/EVA or molded pulp; thermoformed PET/PVC trays also offered for mailers |
| Print Coverage | Exterior only, exterior + interior lid, or full inside and outside |
| Print Methods | Offset, digital, UV, screen or flexographic printing; CMYK and Pantone spot colors |
| Coatings and Finishes | Matte, gloss or soft-touch lamination, aqueous coating, foil stamping, emboss/deboss, Spot UV and raised 3D UV |
| Lid Fit | Set by board, dimensions and overlap; confirmed on sample |
| Starting Price | From $1.45 / unit; final price depends on size, board, lid depth, print coverage, inserts and quantity |
| Minimum Order | 500 units |
| Standard Production | 7 days from approved proof |
| Rush Production | Available on request |
| Shipping | Ships flat, USA and worldwide |
Roll End Box with Lid vs Rigid Two Piece Box
Both open by lifting a lid off a base; the materials and economics differ.
| Attribute | Roll End Box with Lid | Custom Two Piece Box |
|---|---|---|
| Construction | Folding/corrugated board, rolled walls | Greyboard core wrapped in paper |
| Arrives | Flat, folded up at packing | Fully set up |
| Starting price | From $1.45 / unit, 500 minimum | From $2.85 / unit, 500 minimum |
| Can ship as the parcel | Yes, in corrugated with sealing as needed | Usually inside an outer shipper |
| Best fit | Shipped kits and apparel with a full-lid reveal | Keepsake retail and gift boxes |
How It Compares to Other Mailer Structures
| Attribute | Roll End with Lid | Roll End Tuck Top | Roll End Tuck Front | Roll End 3 Flap Lock |
|---|---|---|---|---|
| Pieces | Two | One | One | One |
| Lid | Lifts fully off | Attached, tucks at the top | Attached, locks at the front | Attached flaps interlock |
| Access | Whole top at once | Lid swings back | Lid swings back | Flaps unfold in sequence |
| Shipping seal | Tape, label or band as specified | Optional | Optional | Optional |
What Size Roll End Box with Lid Do You Need?
Work from the product to the base, and from the finished base to the lid. The base inside holds the product with clearance, its rolled walls add two board layers per side, and the lid's inside must clear that outer base while setting how far down it reaches.
How Base and Lid Sizes Relate
The figures below are planning references, not fixed manufacturing rules; final allowances depend on product shape, insert, board and flute.
| Step | Typical Allowance |
|---|---|
| Product to base inside dimensions | Add about 3–6 mm (1/8–1/4 in) to length and width, 2–5 mm to depth |
| Base inside to base outside | Length and width grow by about four board thicknesses across the rolled walls |
| Lid inside over the base | Base outside plus a small clearance, set on the dieline so the lid slides on without binding |
| Lid depth | Equal to base depth for a full lid, or the visible-band height less for a partial lid |
Board and Flute Reference
| Board | Typical Thickness | Typically Suited To |
|---|---|---|
| Paperboard, about 18–24 pt | About 0.45–0.6 mm | Light presentation boxes, often shipped in an outer carton |
| E-flute corrugated | About 1.1–1.6 mm | Most printed lid-and-base mailers |
| B-flute corrugated | About 2.5–3.2 mm | Larger or heavier kits |
Important: Treat these as reference values. A lid on corrugated board fits differently from one on paperboard, so the lid-to-base clearance is confirmed on a sample, and no friction-tight or slow-lift effect is promised in advance.
If you are unsure, share the product dimensions and weight with the quote request, and the base and lid are sized around them.
Does a Lid Box Need Tape to Ship?
It may. A lift-off lid has no lock, so a box that ships as the parcel may need supplemental sealing: tape, a seal label or a band, specified according to the packed product and shipping method. Inside an outer shipper, the lid can travel unsealed.
