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The classic subscription mailer with rolled double side walls and a front tuck.
Subscription Packs · D2C Brands · Electronics
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Studio ready
E-Commerce & Shipping
Full Overlap Container
Also known as FOL / FEFCO 0203
A shipper whose outer flaps overlap fully for extra stacking strength.
Good for
- Industrial Goods
- Heavy Machinery
- Rough Shipment
- Fragile Sets
Structure
- Overlapping Flaps
- High Stacking Strength
- Tape Needed
Material guidance
Corrugated board is the usual choice: E-flute for mailers, B-flute or double wall for heavier shippers.
Current size: 400 × 250 × 250 mm. Production engine geometry; have your manufacturer approve it before cutting.
The structure, unfolded.
Change the size and the dieline redraws.
- Cut lines
- Fold / crease
- Perforation
- Bleed guide
How a full overlap container is built
The full overlap container (FEFCO 0203): like a regular slotted carton, but the outer flaps are the full box width, so they overlap completely and give a double thickness top and bottom.
Putting it together
- 1Square the box.
- 2Fold the inner flaps, then the overlapping outer flaps, and tape.
- 3Fill and close the top the same way.
Measuring for this style
- Length (L)
- The inside length.
- Width (W)
- The inside width. The outer flaps match it.
- Height (H)
- The inside height.
All sizes are inside dimensions. Add 1 to 2 mm of clearance around the product. How to measure
When to choose it
For heavy, dense or fragile products that need a reinforced top and bottom, and for long, narrow items.
Before you print
- Corrugated adds thickness: the outside is about two board thicknesses larger than the inside on every axis.
- Flutes run vertically on shipping cartons for stacking strength; confirm grain direction with your converter.
- Choose board by weight: single-wall B-flute to roughly 15 kg, double wall for heavier or stacked loads.
Questions
Full Overlap Container FAQs
Short answers about sizing, board and files for this style.
What size should I enter for a Full Overlap Container?
Enter inside dimensions in millimetres, centimetres or inches. Length: the inside length. Width: the inside width. the outer flaps match it. Height: the inside height. Measure the product at its widest points and add 1 to 2 mm of clearance (3 to 5 mm for rigid boxes).
Which material is best for a Full Overlap Container?
Corrugated board is the usual choice: E-flute for mailers, B-flute or double wall for heavier shippers.
How is a Full Overlap Container put together?
Square the box. Fold the inner flaps, then the overlapping outer flaps, and tape. Fill and close the top the same way.
Can I download a Full Overlap Container dieline?
Yes. Open the Full Overlap Container in PW Studio, set your size and board, and export a print-ready PDF, SVG or DXF with cut, crease and bleed lines on separate layers. It is free and needs no account.
What else is a Full Overlap Container called?
It is also known as FOL / FEFCO 0203. For heavy, dense or fragile products that need a reinforced top and bottom, and for long, narrow items.
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