Custom Display Mailer Boxes
Custom display mailer boxes that travel as a sealed shipper and open into a counter display — tear-away front, printed interior, sized to your product count — from 100. Dieline and price the same working day.
One box for the courier and the counter
- Board
- E flute white-lined; B flute for heavier counts
- Builds
- Tear-away front, fold-back lid header, sleeve over tray
- Sizing
- Retail count of 6, 12 or 24; divider or stepped platform
Get a price for Display 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.
How the box converts
The tear-away is the common one. The perforation holds in transit and tears with a pull, and it is sampled before the run.
| Tear-away front | A perforated panel on the front and lid; removed in one pull to reveal the product |
|---|---|
| Fold-back lid | The lid folds behind the box to become a printed header |
| Lift-off sleeve | A plain outer sleeve comes off a printed display tray |
Sizing to the count
The box is sized to hold a retail count — 6, 12 or 24 units — in a layout that displays them, which usually means one or two rows facing forward. The product dimensions and the count set the box; a divider or a stepped platform holds the units upright and lifts the back row. Our display boxes for counters and shelves cover the non-shipping versions.
Board that ships and then stands
- E flute with a white top liner — prints well and holds its shape as a display.
- B flute for heavier products or a larger count, with a printed liner.
- A crash-lock or glued base so the box stands square with the weight in it.
- Corner reinforcement on the back panel where the header stands up.
Print for two moments
The outside is the shipper: the brand, a "display inside" message and handling marks. The inside — the back panel, the header, the floor — is the display and takes the effort: full color, the product name, the price point. Inside print on a display mailer is not optional; it is the point.
Show the tear line on the proof against the interior artwork. The torn edge is what the shopper sees at the front.
Who uses display mailers
Brands supplying independent retailers, cafés and salons: snack and confectionery makers, cosmetics, small electronics accessories, greeting cards. A retailer ordering a dozen of something gets a display without asking for one, and the brand controls how the product looks on the counter.
Display 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 white-lined; B flute for heavier counts
- Builds
- Tear-away front, fold-back lid header, sleeve over tray
- Sizing
- Retail count of 6, 12 or 24; divider or stepped platform
- Full color inside; brand and handling marks outside
- Perforation
- Set on the die; sampled before the run
- Base
- Crash-lock or glued; reinforced back panel
- Minimum
- 100 boxes
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 display 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: display 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 Display 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 display 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 does a display mailer work?
It ships sealed like any mailer. The retailer tears off a perforated front panel and the box becomes a counter display with the product facing out.
Will it open during shipping?
Not if the perforation is set right, which we sample before the run.
How many units does it hold?
Whatever retail count you sell in — 6, 12 or 24 are common — laid out in rows that face forward.
Is the inside printed?
Yes, always. The inside is the display, and it carries the full-color artwork.
What board do you use?
E flute with a white liner for most; B flute for heavier products.
What is the minimum order?
100 boxes.
Can there be a header above the product?
Yes, with a fold-back lid that stands up behind the display or a printed back panel that rises above it.
Does it ship flat?
Yes, with the divider or platform flat inside, and it folds up at packing.
Can it hold a stepped display?
Yes, a stepped platform lifts the back row so every unit is seen.
Do you send a dieline?
Yes, with the quote, showing the tear line against the inside artwork.
Do you keep the die?
Yes, so reorders skip the tooling.
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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