Custom Mailer Boxes
Ship your products safely and in style with our custom mailer boxes. We combine durable materials with high-quality printing to create an unforgettable unboxing experience and builds your brand with every delivery
Types of Custom Mailer Boxes We Supply
Cardboard Mailer Box
This style of custom mailer box is perfect for e-commerce packaging, especially for clothing or curated gift sets. You can add a clear window on the lid to hold a thank you card and choose a vibrant color print inside and out to make your brand memorable.
Kraft Mailer Box
The classic kraft mailer box is a strong and affordable choice for shipping a wide variety of products for your online store. These versatile corrugated mailer boxes look great with a simple one-color logo printed on the top for clean and effective branding.
Custom Mailer Box With Insert
As the perfect subscription box packaging, this mailer uses a custom-fit insert to hold multiple items like bottles and apparel securely in place. To create a luxury feel, you can add a matte black finish and print a surprise message on the inside lid.
Holographic Mailer Box
Make a bold statement with a holographic mailer box that shines with rainbow colors, creating an unforgettable unboxing experience. This eye-catching style of printed mailer box is ideal for beauty products or influencer kits and needs no extra printing to stand out.
Pillow Box Mailer
Custom pillow boxes offer a unique and elegant way to package small, lightweight items like jewelry, scarves, or gift cards. You can enhance their curved shape with a metallic paper finish or by adding a foil-stamped logo for a touch of luxury.
Flat Mailer Cardboard Box
Our flat literature mailers are designed to ship important documents, art prints, or books safely without bending. These custom shipping boxes are easy to assemble and can be made from sturdy white or brown corrugated cardboard to protect your items.
Still not finding what you’re looking for?
Contact our consultants for more available products.
Your Dedicated Mailer Box Manufacturer
Strong Construction That Protects Your Products
We make our mailer boxes from sturdy, corrugated cardboard. This material has a wavy layer inside that acts as a cushion, protecting your items from bumps and drops during shipping. We can help you select the right thickness for your specific products, ensuring you get the protection you need without paying for more than necessary.
Your Brand’s First Impression Very Important
Your mailer box packaging is more than just a container; it’s the first physical experience a customer has with your brand. A beautiful box gets customers excited before they even see what’s inside.
We offer high-quality custom mailer box printing on both the inside and outside. You can add your logo, brand colors, or a special thank-you message. This turns a simple delivery into a memorable unboxing experience that customers will love—and might even share on social media. Let us help you create a professional custom printed mailer box that leaves a lasting impression.
Popular Finishing Options for Custom Mailer Boxes
Glossy lamination adds a durable, water-resistant shine to a mailer box. This makes it perfect for a subscription box brand. The brand can create a vibrant and exciting unboxing experience right from the doorstep.
Matte lamination offers a scuff-resistant, premium finish. It is the ideal choice for a high-end fashion or beauty brand. This finish makes the mailer box itself feel modern and luxurious upon arrival.
A simple varnish is the most cost-effective way to seal the ink on a mailer box. It is a practical choice for high-volume e-commerce businesses. These businesses need basic print protection for their shipping boxes.
What You Need to Know : Custom Mailer Boxes
Part 1: Flute Selection (Strength vs. Finish)
Mailer boxes are made of Corrugated Board. The “Flute” (the wavy middle layer) determines the strength.
E-Flute (1.8mm): The “Retail” Choice.
Best for: Subscription boxes, cosmetics, jewelry.
Pros: Thinner profile, smoother surface for high-quality printing, takes up less storage space.
B-Flute (2.8mm): The “Heavy Duty” Choice.
Best for: Heavy items (glass jars, shoes), long-distance shipping.
Pros: Superior crush resistance and cushioning. It protects products better but looks slightly rougher than E-Flute.
Part 2: Printing Methods (Budget vs. Quality)
Flexography (Direct Print):
Best for simple logos on Kraft boxes. It’s cost-effective for high volumes but cannot print photo-realistic images.
Offset Litho-Lamination:
The premium choice. We print on a smooth paper sheet first, then laminate it onto the corrugated board. This allows for magazine-quality images and luxury finishes like Foil Stamping or Spot UV.
Part 3: Saving Shipping Costs (Dimensional Weight)
The Trap: Couriers often charge by “Dimensional Weight” (Size), not just actual weight. A box that is 2cm too big can jump you to the next price tier.
The Fix: We engineer “Snug-Fit” sizes. We measure your product layout exactly to minimize empty air space, saving you thousands in annual shipping fees.
Part 4: The “Locking” Security
Ear-Locks: Our mailers feature sturdy Front Ear-Locks that snap into the side walls. This keeps the box securely closed during transit without needing excessive tape, creating a cleaner unboxing experience for your customer.
Cooperation Process for Custom Mailer Boxes
Technical Confirmation
1 Day
- Review of mailer box style (e.g., tuck-top, roll-end) and shipping dimensions.
- Consultation on corrugated material (e.g., E-flute, B-flute) for durability and print finishes (matte, gloss).
- Feasibility analysis for custom inserts designed to hold products securely during transit.
Sample Making
2-7 Days (Depends on Style)
- White dummy to approve the structure, test the self-locking mechanism, and check overall sturdiness.
- Color sample to verify print quality on the corrugated material and color accuracy.
- Complete pre-production sample to simulate the real shipping and unboxing experience.
- Full QC report detailing dimensions, material grade, and insert fit.
Deliver Samples
3-4 Days to Arrive
- DHL
- FedEx
- UPS
Sample Confirmation
1-2 Days
- Final sample review, focusing on shipping durability, print accuracy, and ease of assembly.
- Confirmation of all technical specifications, including flute type and print finishes.
- Production schedule planning upon formal sample approval.
Most Popular Questions For Custom Mailer Boxes
What is your minimum order quantity for a custom printed mailer box?
Our typical minimum order for a custom printed mailer box is 500 units. Ordering at this volume allows us to offer better pricing, giving you a lower cost per box and making it an efficient choice for growing brands.
How do we start the design process for our customized mailer box?
The process is simple. Once we know the size you need, we provide a flat design template (a dieline). Your designer can place your artwork on this template, which ensures your logo, colors, and messages are printed exactly where you want them on your customized mailer box.
Do you offer eco-friendly options like a kraft mailer box?
We do. Many brands choose our kraft mailer box option, which is made from recycled materials and is fully recyclable. We also offer printing with soy-based inks to create sustainable custom mailer box packaging that aligns with environmentally-conscious values.
What is the typical production time for an order of custom mailer boxes?
Generally, production for an order of custom mailer boxes takes about 10-15 business days after you approve the final design proof. Shipping time will be in addition to that.
What makes a custom mailer box better than a plain, standard one?
A standard mailer box gets the job done, but a custom mailer box builds your brand. It creates a premium experience, makes your package instantly recognizable, and turns a simple delivery into a powerful marketing opportunity that customers remember.
What material do you use to ensure our products are safe in a corrugated mailer box?
We build our mailer boxes from durable, corrugated cardboard. This material has a wavy inner layer that acts as a cushion to protect your items from bumps and drops during shipping. We can help you choose the right thickness to ensure your products are secure without overspending.
How extensive are the options for custom mailer box printing?
Our custom mailer box printing capabilities are very flexible. We can print high-quality designs on both the outside and inside of the box. This allows you to create a fully branded mailer box that offers a memorable unboxing experience for your customers.
Can you create a custom mailer box with inserts to hold our products in place?
Absolutely. We specialize in creating a mailer box with insert options. These custom mailer box inserts are designed to fit your specific products perfectly, preventing them from moving around during transit and giving your packaging a professional, organized look.
Related Product to Custom Mailer Boxes
Subscription Box
Clothing Box
Cosmetic Box
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