Custom Mailer Boxes
from $0.62 / unitStarting price per unit, shipping included. Your price depends on quantity, size, material and finishes, and drops as quantity grows. The final price comes with your quote, and it includes shipping.
Custom mailer boxes are one-piece corrugated boxes with an attached lid and tuck closure, designed for shipping, subscription boxes, gifts and retail presentation. They can be made to fit the product and printed inside, outside or both. Compare the mailer styles below, then share your dimensions, quantity and artwork requirements for a project-specific quote.
- Custom sizes
- Free design support
- Low minimums
Request a Quote
Tell us what you need. No payment, no obligation.
Quick specs
- Sizes
- Custom, made to your product's dimensions
- Minimum order
- 100 units
- Material
- Corrugated board with a printed top sheet
- Corrugation
- E-flute (1.2–2 mm) or B-flute (2.5–3 mm)
- Printing
- CMYK or Pantone; outside, inside or both, with no extra charge for adding colors
- Coating
- Varnish (water-based) or lamination
- Finishes
- Matte, glossy, satin or soft touch; foil stamping, embossing or debossing and spot UV available
- Closure
- Depends on the style: ear locks (Standard, No Dust Flaps), built-in adhesive strip with a tear strip (With Adhesive), three flaps (3 Flap Lock), self-locking lid (With Lid), no ear locks (No Flaps)
- Shipping
- Ships flat
- Assembly level
- Some assembly required
- Suitable as shipping box
- Yes, can be used as shipping box
- Printing technology
- Offset (litho) printing; digital printing is available on request for small runs
- Support for inserts & dividers
- Custom Box Inserts, Custom Box Dividers, Custom Box Partitions
- Available samples
- Structural Sample, Simplified Sample, Pre-Production Sample, Digital Print Proof, Press Proof
- Delivery
- 5–7 working days, plus 4–5 working days for delivery; larger or more complex orders can take longer
- Design support
- Free design support, proofing and 3D preview
- Free dieline templates
- Mailer Boxes dielines
Details
- MOQ from 100 units
- Full-Color Printing
- Free Artwork
- Quick Turnaround
Styles to Fit Your Needs
Below are some styles for custom mailer boxes for your products to choose from.
Technical Specs: Mailer Boxes
An outline of the common custom options available for mailer boxes.
Corrugation
Corrugations, those wavy lines in cardboard (also called flutes), are key to its strength. Glued between flat sheets of paperboard, they create a sturdy structure that protects your packages.
| E-flute | Frequently chosen, it features a flute thickness ranging from 1.2 to 2mm. |
|---|---|
| B-flute | Perfect for bulky boxes and weighty objects, offering a flute thickness between 2.5 and 3mm. |
Materials
Printed designs are applied to these foundational materials, which are subsequently adhered to corrugated board. Recycled stock options are available on request.
| White | High-quality printing results from using Solid Bleached Sulfate (SBS) paper. |
|---|---|
| Brown kraft | Unbleached brown paper, best suited to black or white printing. |
Printing
Choose the color system that suits your artwork and brand.
| CMYK | CMYK stands as the most common and budget-friendly color scheme in printing. |
|---|---|
| Pantone | Prints brand colors accurately and is a step up from CMYK. |
Coating
To keep your printed designs safe, a special coating is added that prevents scratches and scuffs.
| Varnish | A water-based coating that protects less than lamination. |
|---|---|
| Lamination | A plastic coated layer that offers protection against cracks and tears. |
Finishes
Choose a finish to change how the surface looks and feels.
| Matte | Featuring a smooth and non-reflective surface, this design provides an overall softer look. |
|---|---|
| Glossy | Glossy and reflective, this surface tends to highlight fingerprints more. |
| Satin | Semi-glossy, striking a balance between a matte and glossy appearance. |
| Soft touch | Looks like a matte finish but feels soft and velvety to the touch. |
Free Design Support
Our free design support covers everything from fine-tuning details to adjusting layouts. Our team helps you get your design right at no extra cost.
Full-Color Printing
Print your design in full color. With CMYK offset (litho) printing, you can use as many colors as you need without extra charges or hidden fees. Design, proof and print in one straightforward process.
3D Proofing
Review a 3D digital proof before production to check the layout, artwork placement and overall presentation. Changes can be requested during the proofing stage before final approval.
How It Works
Share Your Requirements
Send us your required or product dimensions, preferred box style, required quantity, delivery location, and artwork.
Review Your Quote
We will prepare pricing based on the selected size, material, printing, finishing, and quantity.
Approve Dieline & Artwork
Review the box layout and artwork before production begins.
Production and Delivery
After approval, your boxes move into production and are shipped to your specified location.
Versatile and Durable
Custom mailer boxes are made from corrugated cardboard. They are lightweight but sturdy, which helps your products arrive safely, and you can print full-color designs inside and out.
Enhance and Secure Your Products in One Step
Choose your board and finishes to get the look and quality you want from your mailer boxes.
Mailer Boxes Vs. Shipping Boxes: What’s the Difference?
Mailer Boxes
Mailer boxes are one-piece boxes that snap together without tape or glue, which makes them practical for retail displays, gifting and ecommerce. They are sturdy enough for shipping and suit subscription boxes.
Shipping Boxes
Shipping boxes are built for heavy-duty tasks. Unlike mailers, they require packing tape for secure top and bottom closure. Designed to withstand the rigors of shipping and warehousing. With custom printing, these boxes do more than protect your products, they carry your brand message throughout their journey.
Choose the box style that suits your needs.
Related Packaging to Make Your Mailer Boxes Special
- Packaging Sleeves
Custom sleeves give your mailer boxes a seasonal or branded upgrade at a low cost.
- Custom Inserts
Custom inserts keep products secure and organized, and can be designed to fit your mailer boxes.
- Product Dividers
Keep products organized and damage-free with dividers. Perfect for multi-item shipments and a clean presentation.
- Stickers or Seals
Enhance design and ensure authenticity with branded stickers and seals.
- Cards or Flyers
Add a personal touch with custom cards or flyers, finished with ribbon accents.
- Promotional Flyers
Add flyers to your mailer boxes. Announce new products, share discounts, or tell your brand story.
- Tissue Paper
Branded tissue paper wraps your products and adds protection inside the box.
Frequently Asked Questions
What are custom mailer boxes?
Custom mailer boxes are one-piece corrugated boxes with an attached lid and tuck-style closure. They can be made to fit a product or shipment and printed outside, inside or both. Common uses include ecommerce orders, subscription boxes, gifts and retail presentation.
Which mailer-box features should I compare?
Compare the closure style, corrugated flute, inside dimensions, dust flaps, adhesive or tear strips, printing area and whether the product needs an insert or divider. The best structure depends on product weight, protection needs, packing process and presentation.
What is the difference between a mailer box and a shipping box?
A mailer box is a presentation-ready corrugated structure with an attached lid and tuck closure. A shipping box is a broader transit-box format and often requires tape for closure. Product weight, stacking, handling and the shipping journey should guide the choice.
Can a mailer box include inserts or dividers?
Yes. Custom inserts and dividers can position, separate or protect products inside a mailer box. Share the product dimensions, weight, arrangement and protection requirements so the internal components can be evaluated with the box structure.
What information is useful for a mailer-box quote?
Provide the product type, finished or inside dimensions, quantity, preferred mailer style, artwork status, printing surfaces, finishes, insert requirements and delivery destination. Reference images, sketches, artwork or dielines can be attached when available.
How much do custom mailer boxes cost?
Pricing starts from $0.62 per unit. Final pricing depends on the box dimensions, corrugated flute, quantity, printing, coatings, finishes, inserts and delivery destination. Request a quote for project-specific pricing.
Ready to start your packaging project?
We reply within 1 business day, and quotes include shipping.
+1 (312) 910-5253Monday–Friday, 9:00 AM to 6:30 PM CT