Custom Mailer Boxes

What is a mailer box?

A mailer box is a one-piece corrugated box that folds into shape without glue or tape. The lid tucks into the front, and rolled side walls with dust flaps hold everything square. Because the walls are double thickness, a mailer feels solid in the hand and protects products in the mail, which is why it has become the standard box for direct-to-consumer brands.

When to choose a mailer box

• You ship orders straight to customers and want the box itself to carry your brand.
• You run a subscription or monthly box and want a consistent unboxing moment.
• You build gift sets, PR kits or influencer packages.
• Your products are light to medium weight and fit a fairly shallow box.

For heavy items or bulk freight, a regular slotted shipping box or a double wall box is usually the better fit.

Materials and finishes

Most mailers are made from E-flute corrugated, a thin flute that folds crisply and prints well. B-flute is thicker and adds crush strength for heavier contents. You can choose brown kraft liners for a natural look or white liners for brighter color. Popular options include:

• Full-color print outside, inside or both
• Matte or gloss coating
• Foil stamping or spot accents on the lid
• Custom inserts to hold products in place

Design tips

• Print the inside of the lid: it is the first thing a customer sees when the box opens.
• Keep text and logos away from fold lines so nothing wraps awkwardly.
• Brown kraft shifts colors darker, so test bright brand colors on white board if they matter.
• Measure your product and add room for any insert or tissue before you pick a size.

How ordering works

Tell us your inside dimensions, quantity, material and print, and we reply with pricing. Our team helps set your artwork on the dieline, and you approve a digital proof before anything prints. Our production partner then makes the boxes to your exact size and ships them to your door anywhere in the USA or Canada.