Custom Assorted Mailer Boxes
Custom assorted mailer boxes — two to five sizes of self-locking mailer planned as a family for your order profile and printed to one design — from 100 per size. Dieline and price the same working day.
A shop needs three mailers, not one, and they should look like a set
- Board
- E flute; B flute for the large; white liner or kraft
- Builds
- Self-locking mailers in 2–5 sizes; shared die where footprints match
- Planning
- Sizes chosen from the order profile; postage bands checked
Get a price for Assorted Mailer Boxes
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Planning a size run
Send a month of orders as a list of contents, and the sizes are chosen so that most orders fall into the smallest box that holds them without void fill.
| Small | One item; letterbox height if the product allows; the most-used size |
|---|---|
| Medium | Two or three items; the standard parcel |
| Large | A bundle or a large item |
| Extra | A gift set or a seasonal box; optional |
Sharing what can be shared
Sizes in a run share a print system — the same artwork scaled, the same inside print — and where two sizes share a footprint they can share a die with a depth change. The saving is in the print setup and the freight, and the result on the doorstep is a box that matches whatever was ordered. Our mailer boxes in every construction cover the single box in detail.
Board and the largest size
- E flute for the small and medium; B flute for the large if it carries weight.
- A white liner for full color across the set; kraft for one or two colors.
- Self-locking lids on all sizes, so no tape at any bench.
- Inside print on every size, the same design, so the unboxing is consistent.
Quantities per size
The order profile sets the quantities: perhaps 500 small, 300 medium, 100 large. Each size has its own minimum of 100 and its own price, and the set is quoted as one. Reorders are by size, from the kept dies, as each runs down.
A postage band often sits between two sizes. We check the carrier's bands and nudge a size under one where it saves money on every parcel.
Brands that ship in a family
Apparel, cosmetics, food and drink, homewares, subscription and gift brands. Anyone whose orders vary in size, which is everyone selling more than one thing.
Assorted Mailer Boxes — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- E flute; B flute for the large; white liner or kraft
- Builds
- Self-locking mailers in 2–5 sizes; shared die where footprints match
- Planning
- Sizes chosen from the order profile; postage bands checked
- One design system across sizes; inside print on all
- Quantities
- Per size from the order profile; 100 minimum each
- Reorders
- By size from kept dies
- Minimum
- 100 boxes per size
On every job
- Print process
- Flexo in one to four colors straight onto the liner; litho-lamination where the box needs full color or a photograph.
- Color
- Flat colors on kraft. Full color needs a white top liner or a laminated sheet, because brown shifts every color warm.
- Tolerance
- Cutting plus or minus 1.5 mm. The flute compresses, so corrugated runs wider than folding board.
- Tooling
- No die on a regular slotted box, which is cut on a slotter. Die-cut mailers and trays need one, made once and kept.
- Food contact
- Food-grade liners and a vented build where the box carries hot food.
- Sustainability
- High recycled content through liners and flute as standard, and the box recycles whole if it is sealed with paper tape.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build assorted mailer boxes on
Corrugated is a fluted sheet glued between two liners, and the flute decides nearly everything: how it prints, how it dents, how high it stacks. These are the grades we run.
E flute
About 1.5 mm. Prints well and folds crisply; dents under a stack. Retail boxes, mailers and light shippers.
1.5 mm, single wallB flute
About 3 mm. The working default for parcels — takes print reasonably and stacks reasonably. Most shipping boxes are B.
3 mm, single wallC flute
About 4 mm. More cushioning than B, slightly less stacking strength per weight. Common on grocery and produce cases.
4 mm, single wallBC double wall
B and C glued together, about 7 mm. Heavy or fragile goods, pallet stacking, anything over roughly 15 kg.
7 mm, double wallKraft liner
Brown, strong, absorbent. One or two flat colors flexo print well on it; photographs drink into the brown and go muddy.
Outer and inner linerWhite top liner
A bleached outer liner for full-color print on corrugated. Costs more and marks more easily than kraft.
Outer liner onlyRecycled-content corrugated
High post-consumer fiber through liners and flute. The default for shippers; a slightly greyer brown and no loss of strength at grade.
All flutesCoated and water-resistant
A coating or a wax-free barrier liner for damp stores and cold chains. Check the recycling stream before printing a claim on it.
B and C fluteNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Corrugated takes fewer finishes than folding board, and the ones it takes it takes well.
Flexo on kraft
One or two flat colors straight onto brown. Cheap, fast, honest.
Litho-lamination
An offset sheet glued to the flute: full color and photographs on a shipper.
Aqueous varnish
Scuff resistance with no film, so the box still recycles whole.
White top print
Full color flexo on a bleached liner; brighter, and it marks more easily.
Inside print
A second pass on the inner liner — the panel a customer sees first.
Printed tape seal
The brand applied at the last moment, on paper tape that recycles with the box.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a corrugated box against the carrier, not the catalog: assorted mailer boxes
Corrugated is cut to your internal size, so the box goes round the product rather than the product going into a stock size. That is where the money is: a box 20 mm smaller each way is often a whole postage band cheaper.
- Internal dimensions
- Length, width and depth of the space you need. Board thickness is added outside that, and the flute is thicker than people expect.
- Clearance and void fill
- 5–10 mm a side for a rigid product. Size it properly and you need no void fill at all, which is cheaper and better received.
- Stacking
- Tell us how high the boxes stack on a pallet or a shelf. Edge crush grade is specified from that, not guessed.
- Weight
- The contents weight sets the flute and the liner grade. Over about 15 kg we move to double wall.
- Score allowance
- Corrugated needs more room at the folds than boxboard. The dieline accounts for it; a box drawn from flat dimensions comes out tight.
- Cutting tolerance
- Plus or minus 1.5 mm on corrugated, wider than folding board because the flute compresses.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Assorted Mailer Boxes in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about assorted mailer boxes? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
How many sizes do I need?
Usually three — small, medium, large — chosen from a month of orders so most fall into the smallest box that holds them.
Do the sizes share a die?
Where two share a footprint, yes, with a depth change. Different footprints are different dies.
Will the boxes match?
Yes, one print system scaled to each size, inside and out.
What is the minimum per size?
100 boxes.
Can I order different quantities per size?
Yes, from the order profile — more of the small, fewer of the large.
Do you check postage bands?
Yes, and nudge a size under a band where it saves on every parcel.
What board is used?
E flute for small and medium, B flute for a large that carries weight.
Do all sizes self-lock?
Yes, no tape on any size.
Can I reorder one size?
Yes, from the kept die, as it runs down.
Can a seasonal box be part of the set?
Yes, as an extra size or a print change on an existing one.
How do I give you the order profile?
A month of orders as a list of contents. We size from it.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
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