Custom Mailer Boxes

Custom mailer boxes are sturdy, front-opening boxes designed to ship products safely while also looking on-brand and professional. Unlike plain shipping cartons, they’re sized around your product, printed with your logo and design, and built to create a smooth, satisfying unboxing experience.

Regular shipping boxes are usually simple top-load cartons, meant only for transport. Mailer boxes, on the other hand:

• Open from the front with a tuck-in lid
• Lock into place without extra tape in many cases
• Are often fully branded inside and out
• Are designed for both protection and presentation

That’s why custom mailer boxes are so popular for ecommerce, subscriptions, PR kits, and gifting.

Custom mailer boxes work well for a wide variety of products, including:

• Apparel and accessories
• Beauty, skincare, and wellness items
• Books, stationery, and lifestyle products
• PR and influencer kits
• Monthly subscription boxes
• Corporate gifts and branded merch

If you want your package to arrive safely and feel like a “gift” as soon as it’s opened, a mailer box is a strong choice.

Our custom mailer boxes are made from durable corrugated cardboard, typically in:

• E-flute – thinner, smoother, ideal for smaller items and detailed printing
• B-flute – thicker, stronger, better for heavier or fragile products

You can also choose between white or kraft material, depending on whether you want a clean, bold print surface or a more natural, eco-focused look.

Both are strong and reliable, but they serve slightly different needs:

• E-flute (around 1/16″)
  • Thinner and more compact
  • Smoother surface for sharp, high-quality printing
  • Great for cosmetics, small accessories, and retail-ready boxes
• B-flute (around 1/8″)
  • Thicker and more cushioned
  • Better shock absorption for shipping
  • Ideal for ecommerce, books, and more delicate or heavy items

We can help you choose the best flute based on your product and shipping method.

They can be. Our mailer boxes are made from paper-based corrugated board, and we offer kraft and other eco-conscious options. When you choose recyclable materials and smart design, your custom mailer packaging can be both sustainable and premium-looking.

Yes. You can brand:

• The outside with your logo, colors, and main design
• The inside with patterns, messaging, thank-you notes, or campaigns

You can keep it clean and simple, or go all out with premium touches. Available finishes include:

• Matte or gloss coatings
• Soft-touch lamination for a velvety feel
• Spot UV to highlight logos or key details
• Foil stamping for metallic accents
• Embossing or debossing for raised or recessed elements

These details help your mailer boxes stand out in a big way, especially for luxury, gifting, or PR campaigns.

Yes. Mailer boxes are designed to be quick and intuitive to put together. They ship flat to save space, and with a few folds and tucks, you get a sturdy, self-locking box. Most teams can pack them efficiently without special tools or equipment.

When properly sized and paired with the right flute and board strength, mailer boxes offer excellent protection. They:

• Hold their shape during transit
• Resist crushing and bending
• Cushion products from minor impacts

They’re perfect for subscription boxes. Mailer packaging:

• Stacks well for monthly fulfillment
• Opens nicely for that “reveal” moment
• Gives you plenty of real estate for branding and messaging
• Can be sized to reduce extra filler and shipping waste

Yes. Kraft mailer boxes are a great option when you want:

• A natural, earthy aesthetic
• Packaging that visually supports eco-friendly branding
• A strong base for simple or minimalist designs

You can customize almost everything, including:

• Size & shape – tailored to your product dimensions
• Material – white, kraft, or specialty corrugated stock
• Printing – full-color outside, inside, or both
• Finishes – matte, gloss, soft-touch, foil, embossing, debossing, spot UV
• Details – branded inserts, custom tape, or extra messaging inside

Yes. We support:

• Small runs – ideal for new brands, limited editions, or test launches
• Bulk and wholesale mailer boxes – perfect for growing ecommerce stores and subscription services

A well-designed custom mailer box can actually help control shipping costs by:

• Reducing unused space inside the box
• Minimizing the need for extra outer cartons
• Using the right flute and board strength for your product weight

To get an accurate quote, it helps to share:

• The product dimensions and weight
• The quantity you’re looking to order
• Preferred material (white or kraft, E-flute or B-flute)
• Whether you want inside printing or just outside
• Any special finishes (foil, embossing, spot UV, etc.)

Production time depends on your design complexity, order size, and finishes. Generally, the process looks like this:

• Confirm the box style, size, and material.
• Approve the dieline and final artwork.
• We print, cut, fold, and glue your boxes.

Yes. You can request samples or prototypes to check print quality, color, structure, and overall feel in person. This is especially useful for new branding, premium finishes, or important campaigns where every detail matters.