A2 / A4 size Cardboard Envelope Mailer - Expandable Envelopes

Indestructible A4 Size Cardboard Envelope - Fits comic books, DVDs, brochures, calendars & more

The Lil A2 is a Royal Mail large letter A4 envelope and capacity mailer, built to handle comic books, CDs, DVDs, brochures, calendars and A4 photographs through the postal system. As a genuine CD/DVD mailer in one, it's designed to accommodate Royal Mail's large letter tariff flat packed, or expand into a capacity mailer within the small parcel tariff, so you're never overpaying to post an A4 item. For the full picture on why this matters, see our large letter packaging guide.

With its robust, natural finish, your customers open attractive packaging to receive their items in the condition you posted them in. Manufactured using E flute corrugated cardboard with special folds that buffer the edges, minimising the risk of impact damage. Our leading peel'n'seal / tear strip system makes sealing and opening effortless. Read more on safely packaging and mailing CDs and DVDs in our knowledgebase.

The corner stiffness of the A2 envelope cuts damage in transit, online retailers report nearly 70% fewer returns and 25% faster packing versus bubble mailers. Over a million of these A2 cardboard mailer envelopes are used every month.

All Lil envelopes are made from 100% recycled material and are 100% recyclable, a plastic free alternative to the bubble mailer. This range was developed alongside one of the internet's largest retailers, so you might recognise it. Explore the wider corrugated envelope range for other flat pack sizes.

Lil Packaging is Europe's largest independent producer of CD/DVD mailers and cardboard envelope mailers, trusted by 10,000+ brands.

Why Choose Our A2 / A4 Size Cardboard Mailer

• Fits everything: one size accommodates comic books, DVDs, brochures, calendars and A4 photographs, no need to stock multiple mailer sizes
• Postage smart: flat packed within Royal Mail's large letter tariff, expanded within small parcel, so you always pick the cheapest rate for the job
• Genuinely indestructible: reinforced corrugated folds absorb impact at the corners, where flat items are most vulnerable to bending and crushing
• Tamper evident closure: peel and seal system forms a permanent bond, so damage or tampering is obvious before the parcel is opened
• Genuinely sustainable: FSC certified, Plastic Free and Zero Carbon as standard
• Proven at scale: developed alongside one of the internet's largest retailers, over a million used every month

Product Specification

• Size: 334 x 234mm flat, expands to 294 x 194 x 40mm
• Material: E flute corrugated cardboard, approx 1.5mm thick
• Closure: Tamper evident peel and seal (permanent bond)
• Postal fit: Designed to accommodate Royal Mail's large letter tariff flat packed, or the small parcel tariff when expanded (Large Letter tariff)
• Certifications: FSC certified, Plastic Free, Zero Carbon

Your packaging is the first time your customers physically experience your product. Getting it right is your chance to make the best first impression, we help you do just that.

Go on... burst that bubble!

What size items does the A2 envelope fit?
The A2 is sized for A4 items, comic books, DVDs, brochures, calendars and photographs. Flat packed it measures 334 x 234mm, and it expands to 294 x 194 x 40mm to accommodate slightly thicker items without needing a different mailer size.

Is the A2 suitable for comic books and DVDs together?
Yes. The A2 is built to handle comic books, DVDs, Blu-rays, brochures and calendars within the same flat pack size, so you can standardise on one mailer across a mixed A4 product range rather than stocking separate sizes.

Does the A2 fit Royal Mail's large letter tariff?
Yes, flat packed the A2 sits comfortably within Royal Mail Large Letter Maximisers - Lil Packaging, the cheapest posting option available. If you need the expanded box form for a bulkier item, it moves into the small parcel tariff instead, still cost effective versus a rigid box.

What's the difference between the A2 and other A-range sizes?
The A2 is sized specifically around A4 dimensions. If you need something smaller for single discs, the A1 DVD/A5 mailer covers that, or for larger flat items, the full Cardboard Envelopes Wide Opening A Range - Lil Packaging covers sizes up to A5.

Is the A2 mailer plastic free and recyclable?
Yes, the A2 is made from 100% recycled corrugated cardboard and is fully recyclable. It's certified Plastic Free Packaging - Lil Packaging and forms part of our Zero Carbon Packaging - Lil Packaging packaging range, so it's a genuine sustainable alternative to bubble mailers.

How durable is the A2 against damage in transit?
The corrugated construction includes reinforced folds at the corners, the point where flat items like comics and DVDs are most likely to bend or crack in transit. Combined with the tamper evident peel and seal closure, retailers using the A2 report meaningfully fewer returns and faster packing times than with bubble mailers.

How is the A2 sealed and opened?
The A2 uses our peel and seal / tear strip closure system, a permanent adhesive bond for tamper evident security, paired with a tear strip for quick, clean opening on the customer's end, no scissors or tape needed.