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Custom Mailer Boxes For Every Business

Our custom mailer boxes are designed for businesses that want their packaging to look sharp, protect the content inside well, and feel professional to open. Each of these boxes is made to look refined, hold its shape during transit, and make for a satisfying unboxing. Your packaging is the first interaction your customer has with your product. The right box sets the tone before it’s even opened, and our custom mailer boxes do just that. These customizable mailer boxes will help you deliver your product in packaging that is thoughtful and on-brand. They’re practical to pack, easy to assemble, and durable enough to keep your items safe all the way to the customer’s door.

Benefits of Custom Mailer Boxes

These printed mailer boxes make your product feel special from the get go. They aren’t just good for packaging but also for retaining client experience. Here is why so many brands use them:

  • Reliable Protection:
    Our custom mailer boxes are durable and strong enough to handle shipping without crushing or bending.
  • Great First Impression:
    These branded mailer boxes make product unboxing all the more engaging for the customer.
  • Custom Fit:
    You can choose the material, size, and layout to match your product perfectly. We offer everything from kraft mailer boxes to luxury mailer boxes.
  • Versatile Use:
    These boxes are perfect for all sorts of packages, including but not limited to retail, PR kits, gifts, and subscription packaging.
  • Lightweight Design:
    They are easy to assemble and lightweight, making them cost-effective to ship.

Features of Our Custom Printed Mailer Boxes

We manufacture custom printed mailer boxes with top-tier printing techniques to elevate your packaging game. Our mailer boxes include:

  • Tuck Top Mailer Boxes:
    Secure closure and easy assembly.
  • Colored Mailer Boxes:
    Available in various shades to match your brand’s aesthetics.
  • Custom Mailer Boxes with Logo:
    Showcase your brand with high-quality printing.
  • Personalized Mailer Boxes:
    Tailored to your specific design and branding needs.
  • Bulk Mailer Boxes:
    Perfect for businesses needing large quantities at wholesale prices.

A Must for Brands Across Different Industries

Blue Box Packaging offers custom-printed mailer boxes, used by many different industries that rely heavily on strong yet stylish packaging:

  • Ecommerce Stores:
    Ship apparel, accessories, or lifestyle goods in protective, attractive packaging that appeals to the customer’s eye.
  • Subscription Businesses:
    Increase your business’s monthly deliveries with custom mailer boxes with logos that boost your company branding.
  • Beauty & Wellness Brands:
    Keep skincare or makeup products safe and well-presented in kraft mailer boxes without any damage during transit.
  • Corporate Gifting:
    Impress your clients with luxury mailer box designs made for premium gifts.
  • Small Businesses:
    We offer affordable, scalable packaging that grows with your brand.
custom-mailer-box-with-inside-printing

E-Flute or B-Flute for Your Mailer Boxes

Our custom mailer boxes are crafted from durable corrugated E-Flute (1/16″) or B-Flute (1/8″), providing reliable protection for small to mid-sized items without requiring extra packaging. These flutes affect the box’s thickness, strength, and cushioning properties.

E-Flute (1/16″ or 1.6mm thick)

  • Thin and compact:
    Ideal for high-quality printing.
  • Better surface smoothness:
    Great for branding and graphics.
  • Moderate strength:
    Suitable for retail packaging, cosmetics, and small items.
  • Less bulk:
    Takes up less storage space.

B-Flute (1/8″ or 3.2mm thick)

  • Thicker and stronger:
    Provides better protection.
  • More cushioning:
    Absorbs shocks well.
  • Common for mailer and shipping boxes:
    Used for e-commerce, books, and fragile products.

Customization Options for Your Mailer Boxes

We offer fully customizable mailer boxes to match your brand’s vision. Our customization options include:

  • Size & Shape:
    Choose dimensions that fit your product perfectly.
  • Printing Techniques:
    Offset printing for vibrant designs.
  • Material Choices:
    Corrugated, kraft, and eco-friendly materials.
  • Finishing Touches:
    Matte, gloss, embossing, debossing, foil stamping, and spot UV.
custom-printed-cardboard-box-with-qr-code

Stylish Mailer Box Designs in All Sizes

Elevate your mailer boxes with our diverse, customizable boxes designed to resonate with your brand and captivate customers.

Tear Strip Mailer Box

Tear Strip Mailer Box

Features a built-in tear strip for easy opening, ideal for secure shipping.

Roll End Tuck Top Mailer Box

Roll End Tuck Top Mailer Box

Sturdy, self-locking box with a tuck-in top flap for secure product packaging.

Roll End Front Lock Mailer Box

Roll End Front Lock Mailer Box

Durable mailer with front locking tabs, ensuring extra security and protection during shipping.

Tab Lock Mailer Box

Tab Lock Mailer Box

Lightweight mailer with side tab locks, offering secure closure without additional adhesives or tape.

Frequently Asked Questions

What are mailer boxes used for?

Mailer boxes are used for shipping, packaging, and presenting products securely and attractively. They’re popular for eCommerce, subscription boxes, PR kits, and retail packaging.

Can I customize the size of my mailer boxes?

Yes, you can order custom size mailer boxes built to fit your product perfectly. Just share your product dimensions, and we’ll design a snug, protective fit.

What materials are available for mailer boxes?

At Blue Box Packaging, we offer a range of materials to suit different branding, shipping, and sustainability needs — from sturdy kraft stock to premium coated boards.

Here are the most popular options:
  • SBS C1S (Solid Bleached Sulfate – Coated One Side): Smooth, bright white surface ideal for sharp printing and a premium retail look.
  • SBS C2S (Coated Two Sides): Glossy or matte finish inside and out—perfect for brands that want a fully printed interior.
  • White Kraft: Clean, durable, and easy to print—great for modern, minimal designs.
  • Natural Brown Kraft: Rustic and eco-friendly; made from unbleached fibers for a natural look and strong structure.
  • Black Kraft: Deep black color through the board; ideal for elegant or minimalist branding.
  • Textured Paperboard: Adds tactile appeal with linen, embossed, or soft-touch finishes that enhance perceived value.
  • Metallic Cardboard: Shiny reflective surface that gives products a luxurious edge.
  • Holographic Cardboard: Iridescent finish that stands out in photos and videos—perfect for creative or influencer packaging.
  • Corrugated Cardboard (E-Flute / B-Flute): Lightweight yet strong; best for shipping mailers that need extra protection.
  • Recycled Paperboard / Eco Mix: Made from post-consumer materials, offering durability with a reduced environmental footprint.

Each material is selected for its balance of appearance, strength, and sustainability, helping your mailer boxes look impressive and perform flawlessly in transit.

Are mailer boxes strong enough for shipping?

Yes, our custom corrugated mailer boxes are designed to handle transit safely while keeping your items protected from damage.

Can I print my logo or design on the boxes?

Absolutely. We offer custom mailer box printing so you can feature your brand logo, design, and colors for a professional, branded look.

What printing options do you offer?

We use high-quality offset and digital printing to produce printed mailer boxes with crisp colors and sharp detail.

Can I order a small quantity for my first run?

Yes, our minimum order quantity starts as low as 100 boxes, perfect for small businesses or new product launches.

Do you offer bulk or wholesale pricing?

Yes, we provide custom mailer boxes wholesale at discounted rates for bulk orders.

Are your mailer boxes eco-friendly?

We offer recyclable, biodegradable, and sustainable materials to help you create eco-conscious custom mailer box packaging.

Do you offer inserts or dividers for products inside the box?

Yes, we provide custom mailer boxes with inserts to keep products organized and protected during transit.

Material Options

Choose from a variety of materials to design mailer boxes that offer both strength and a luxurious look for your products.

sbs-c1s SBS C1S

SBS C1S (Solid Bleached Sulfate) is a premium white paperboard coated on one side, ideal for high-quality printing and colors.

sbs-c2s SBS C2S

SBS C2S is a premium white paperboard, coated on both sides, ensuring premium quality for vibrant printing.

white-kraft White Kraft

Tear and moisture-resistant, made from recycled materials, white kraft paper is an eco-friendly choice, coated on both sides.

natural-brown-kraft Natural Brown Kraft

Natural kraft paperboard, 100% recyclable, offers chemical-free, brown-toned material for eco-conscious packaging solutions.

textured Textured

Perfect for luxury soap boxes, textured paper stock surface ensures high-quality finishes.

black-kraft Black Kraft

Made from recycled materials, black kraft paper offers durability and a stylish, high-end glossy look.

metallic-cardboard Metallic Cardboard

Featuring metallic finishes, provides decorative appeal, for moisture-sensitive products.

holographic-cardboard Holographic Cardboard

With 3D effect, holographic cardboard adds vibrant, color-changing charm to the packaging.

B-Flute B Flute

B Flute corrugated board features medium-depth flutes that offer a perfect balance of cushioning and rigidity. Ideal for shipping and retail packaging, it provides excellent crush resistance for heavier items.

C-Flute C Flute

C Flute corrugated board is known for its thicker profile and strong stacking strength. Commonly used for mailer boxes that require added protection during transit without compromising print quality.

E-Flute E Flute

E Flute corrugated board has a fine flute profile that ensures a sleek, premium look with sturdy construction. Perfect for custom printed mailer boxes where high-quality graphics and structural integrity matter.

Add-on Options

Add an extra touch of elegance and style to your mailer boxes with our premium Add-ons. These options ensure your packaging is visually striking, high-quality, and tailored to your brand’s image.

foiling Foiling

Foiling adds metallic detail to logos and designs, enhancing branding for luxury packaging.

embossing Embossing

Embossing offers a 3D effect by pressing logos and text into paperboard.

debossing Debossing

Debossing presses designs into paperboard, creating an engraved effect ideal for luxury branding and packaging.

spot-uv Spot UV

Fast-drying UV coatings, cured by UV light, offer premium gloss or matte finishes for packaging.

Finishing Options

Personalize your mailer packaging with luxurious details, making your boxes visually striking and perfect for creating a memorable brand experience.

gloss-finish Gloss Finish

A gloss finish enhances colors with a high-shine effect, giving packaging a premium, polished appearance.

matte-finish Matte Finish

Matte finishes offer a sleek, muted surface, enhancing packaging with a modern and subtle elegance.

soft-touch-finish Soft Touch Finish

A soft touch finish delivers a smooth, velvety feel, perfect for high-end packaging designs.

pearlescent-finish Pearlescent Finish

Pearlescent finishes enhance packaging with a subtle shimmer, exuding elegance and high-end appeal.

How It Works

With just a few Steps, design your own boxes!

get a quote
Get Free Quote

Get a free quote on any packaging project instantly, no matter how complex it is.

material selection
Material Selection

We suggest the perfect packaging material for your box once you select the box style.

artwork prep
Artwork Preparation

Share your artwork & design; if not, we will design it based on your suggestions.

production started
Start Production

Once your artwork is approved, we'll begin production. We will support you at every step.

Why Choose BlueBox?

Blue box Packaging is a one-stop facility that offers all kinds of solutions to your personalized packaging needs.

free design
Free Design Support

We offer free of charge design support for flawless packaging boxes.

starting from 100 boxes
Starting from 100 Boxes

Perfect for small businesses: our MOQ starts at 100 units.

fast turnaround
Quick Turnaround Time

We ensure quick delivery without compromising on quality.

free shipping
Free Shipping

No hidden costs—enjoy free shipping on all packaging orders.

Customer Reviews

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Recent Reviews

★★★★★
Grace Marsh Oct 1, 2025
Excellent service and I will continue to use them

Honestly, finding good custom mailer boxes used to be such a headache. Either the quality wasn’t right or the designs didn’t turn out how I imagined. When I came across Blue Box Packaging, things finally got easy. Their team actually listened to what I wanted, helped me fix my design, and made sure everything looked exactly the way I pictured. The boxes came out perfect, strong, neat, and just beautiful. I didn’t have to chase anyone or stress about the process. It was simple, smooth, and totally worth it.

★★★★★
Jennifer Ingram Sep 5, 2025
Best Packaging Supplier

I found the team at Blue Box Packaging to be professional and helpful! their range of styles and materials available for mailer boxes is of the highest quality. i’d love to work with them in the near future!

★★★★★
Mercy Overcomer Feb 10, 2025
Eco-Friendly Solutions

Blue Box Packaging provides a range of eco-friendly materials to choose for packaging. This helped me create inspiring mailer boxes and attract mindful clients. Definitely coming back with more eco-friendly packaging ideas.

★★★★★
David Thomas Aug 12, 2024
Mailer Boxes

I never knew about the customization possible with mailer boxes. Now here I am with the best mailer boxes at my disposal. These are good enough to be used as primary packaging for my apparel business. Highly recommended.

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