- Free physical sample before the full run
- Free dieline and artwork check
- 6–8 business days from approved proof
Custom Mailer Boxes
You deliver an unforgettable unboxing experience and protect your merchandise with custom mailer boxes built for real-world transit. Sturdy interlocking flaps eliminate the need for external tape, giving your packages a clean, professional finish that instantly builds brand trust.
By pairing rugged construction with high-impact graphics using custom corrugated cardboard boxes, you shield products against transit shocks while making every delivery feel like a premium gift. Double-walled side panels add structural strength, preventing crushed corners during postal handling.
Ideal for subscription models and modern ecommerce packaging, these self-locking designs save your fulfillment team valuable packing time. You can choose full-color interior printing to surprise customers the moment they open the lid. Upgrade your shipping strategy, lower return rates due to damage, and turn every customer delivery into a powerful marketing tool with custom-engineered mailers.
Starting from
$0.10
per box · minimum 100 boxes
Product specifications
| Specification Parameter | Technical Details |
| Material Stock | Single-Wall Corrugated Board (E-Flute, B-Flute), Kraft Flute, White Board Flute |
| Thickness / GSM | 1.5mm (E-Flute) to 3.0mm (B-Flute); 350 GSM – 600 GSM face sheets |
| Custom Dimensions | Fully customizable (Length × Width × Height) tailored to product dimensions |
| Printing Options | Offset Lithography, UV Digital Printing, Flexographic Printing (CMYK & Pantone PMS) |
| Finishing & Coating | Matte Lamination, Gloss Lamination, Soft-Touch Coating, Anti-Scratch Film, Water-Based Varnish |
| Add-Ons & Structural Extras | Custom Inserts (Corrugated, Foam, Cardboard), Peel-and-Seal Adhesive Strips, Tear-Strips, Foil Stamping, Spot UV |
| Minimum Order Quantity (MOQ) | 100 units |
Common questions
Do custom mailer boxes need extra packing tape to stay closed during transit?
No. The interlocking dust flaps and front tuck-in lid create a secure seal without exterior tape. Optional peel-and-seal adhesive strips can be added for extra security.
How do corrugated mailers protect heavy or fragile items in the post?
Crush-resistant flute structures absorb shocks and impacts during handling. Double-walled sides create a rigid frame that prevents crushing when packages are stacked in transit.
Can I print high-definition artwork on both the inside and outside of the box?
Yes. Full-color printing is available on both the interior and exterior surfaces. Interior printing lets you display welcome notes, branding details, or custom artwork right when the box is opened.
Will custom-sized mailers help reduce my shipping expenses?
Yes. Right-sizing your mailer boxes to fit your products eliminates excess dimensional weight charges from carriers. It also reduces the need for costly void-fill materials.
Do I need a designer to supply artwork?
Not necessarily. Send us what you have — logo files and a rough idea — and our studio can lay it onto the dieline for you. Full design support is available on request.
Related packaging
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Customization options
Customer reviews
4.8
76 ratings
4.9Print quality4.8Board strength4.7Delivery speed4.8Value4.9Support
PMPriya M.4/2/20265.0
The printed colour matched our brand proof almost perfectly — no washed-out blues like the last supplier gave us. Crash-lock base holds our jars snug with zero rattling in transit.
RARebecca A.2/14/20265.0
Third reorder now. Consistent board quality every single time and the crease lines fold clean without cracking the print.
HLHannah L.3/26/20265.0
Honestly obsessed with how the full-bleed floral print turned out. The matte board feels premium and our unboxing videos have never looked this good.
JPJames P.2/6/20265.0
Needed a small first run to test the market and the low MOQ made it possible. Quality was identical when we scaled to 2,000.
DRDiego R.3/19/20265.0
Ordered a run of activity-kit boxes with a die-cut handle and window — the finish is spotless and the kids love them. Studio sorted the dieline for us in a day.
AKAisha K.1/30/20265.0
Customer service actually replies within a few hours like they promise. They caught a bleed issue in my artwork before it went to print.
AOAmara O.3/11/20265.0
Rigid gift boxes with a soft-touch lid and printed inner — exactly the luxury feel we wanted for our candle sets. Reorder was even easier than the first time.
MVMarco V.1/22/20265.0
Sturdy corrugated that survived a rough courier journey with no dents. The FSC board was a big selling point for our eco-conscious customers.
SCSofia C.2/28/20265.0
The window box with the printed stamp detailing is stunning in person. Turnaround beat the quoted lead time and the samples arrived free before we committed.
CDChloé D.1/15/20265.0
The free dieline template made designing so much less stressful. Everything lined up perfectly on the printed box.