Custom Mailer Boxes
Printed mailer boxes from 100, sized against carrier bands rather than guesswork. Ships flat, opens without a knife, and prints inside as well as out — the cheapest branded surface an ecommerce order has.
The box your customer photographs
Get a price for 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.
- 8styles in this range, each with its own page and price
- 100unit minimum on every style, printed or plain
- 4markets quoted in the delivery currency
- ±1mmcutting tolerance on folding board, checked on a sample
8 styles in this range
Styles we make in this range
Every one below is written up, priced and dielined. Tap a style to see how it is built.
01See the build →Assorted Mailer Boxes
Custom assorted mailer boxes
02See the build →Corrugated Literature Mailers
Custom corrugated literature mailers
03See the build →Ear Lock Mailer Boxes
Custom ear lock mailer boxes that close by locking two tabs into the side walls, from 100 units.
04See the build →Foldable Mailer Boxes
Custom foldable mailer boxes that arrive flat and fold without tape in seconds
05See the build →Mailer Boxes with Inserts
A mailer box protects nothing on its own.
06See the build →Paper Padded Mailers
Custom paper padded mailers with a paper cushion instead of plastic bubble, from 100 units.
07See the build →Self Seal Mailing Boxes
Custom self-seal mailing boxes with a peel-off adhesive strip built into the lid, from 100 units.
08See the build →Tuck Top Mailer Boxes
A tuck top mailer folds up from flat, holds itself shut with a front flap, and is sealed with one sticker.
Side by side
Which mailer boxes style fits
| Style | Board | Build | Minimum | |
|---|---|---|---|---|
| Assorted Mailer Boxes | E flute; B flute for the large; white liner or kraft | Self-locking mailers in 2–5 sizes; shared die where footprints match | 100 boxes per size | Open → |
| Corrugated Literature Mailers | E-flute for most; B-flute for hardcovers and large flats; chipboard stiffener option | Tab lock into the front wall; tear strip on request | 100 boxes | Open → |
| Ear Lock Mailer Boxes | E-flute, B-flute or EB double-wall corrugated; kraft or white liner | Two ear tabs into side-wall slots, dust flaps at the corners; no tape | 100 boxes | Open → |
| Foldable Mailer Boxes | E flute kraft or white-lined; B flute for weight or distance | One-blank self-locking mailer; double side walls; tuck lid | 100 boxes | Open → |
| Mailer Boxes with Inserts | E-flute for retail feel, B-flute where the contents are heavy | See the page | 100 boxes with insert | Open → |
| Paper Padded Mailers | Chosen per job | See the page | 100 mailers | Open → |
| Self Seal Mailing Boxes | E-flute or B-flute corrugated; kraft or white liner | Hot-melt peel-and-seal strip, full lid width, cold-to-heat rated | 100 boxes | Open → |
| Tuck Top Mailer Boxes | E flute for light contents, B flute as the working default | Tuck top mailer; winged roll-end version for heavier contents | 100 boxes | Open → |
Flute grade before anything else
E-flute is 1.5 mm, takes fine print, and folds crisply — it is what most direct-to-consumer brands mean when they say mailer box. B-flute is 3 mm, absorbs far more of a drop, and suits anything above about two kilos. Below E there is F-flute, which prints beautifully and protects almost nothing.
Pick the flute for the weight, then design the print to suit it. A photographic image on B-flute will show the corrugation as fine ridges; on E-flute it will not.
| F-flute (~1.0 mm) | Best print surface, minimal protection, small light items |
|---|---|
| E-flute (~1.5 mm) | The DTC standard — good print, good for up to ~2 kg |
| B-flute (~3.0 mm) | Real cushioning; heavier goods, glass, multipacks |
Printing inside costs almost nothing
The inside of a mailer is the surface a customer looks at longest, and on a litho-laminated box it is one extra pass rather than a second job. A message, a reorder code, a care instruction — anything there gets read, where a leaflet gets binned.
Flexo-printed corrugated is different: inside print means a second setup and it is rarely worth it below a few thousand boxes. Which process we quote depends on your run length, and we will tell you which one you are getting.
Sizing against dimensional weight
Carriers bill the greater of actual and volumetric weight. Every spare centimeter inside the box is charged on every parcel for the life of the SKU, so the cheapest packaging decision most brands can make is to shrink the box by a centimeter.
Bring the product and your carrier. We will size the box to the smallest footprint that still passes a drop, and if a fitted insert would let it shrink further we will say so — see how fitted inserts change the box size.
Length × width × height in centimeters ÷ 5000 is the billable kilo on most international services. Compare it to the real weight before signing off a size.
Closure, and why tape is a decision
- Roll-end tuck-front closes without tape and opens cleanly — the standard DTC choice.
- Full-flap needs tape but takes far more stacking load; better for heavy multipacks.
- Peel-and-seal strips add cost per box and remove a step from your packing bench.
- A tear strip makes opening feel designed and makes the box single-use.
Across the range
What every mailer boxes job runs on
Boards
- Natural kraft
- White SBS
- E and B flute
- Wrapped grayboard
- Food-grade board
- Recycled content
Chosen from what goes in the box and how far it travels. Our notes on recyclable and compostable stocks say which claims each board can carry.
Finishes
- Matte
- Gloss
- Soft-touch
- Foil
- Emboss
- Spot UV
- Kraft
- Textured
Each one is a decision about light on a shelf — the specialty finishes range shows them on real boxes.
Artwork
- Vector PDF or AI, fonts outlined
- 3 mm bleed, 4 mm safe area
- CMYK; a spot color where a match must hold
- Proof on the dieline before press
Files not set up that way are fine — see the guide to preparing print files.
Interactive · five steps · no sign-up
Build your 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 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.
What is the minimum order?
100 mailers. The die is the fixed cost, and it is kept for your reorders.
E flute or B flute?
E flute prints better and dents more easily. B flute is the right default for anything you would be upset to see damaged.
Can you print the inside?
Yes — it is a second pass on board you have already bought, and it is the cheapest branded surface in an ecommerce order.
Will it fit a letterbox?
Only under the depth threshold your carrier sets. Tell us the service and we will size against it.
Can the customer reseal it for a return?
With a second adhesive strip, yes. In apparel and footwear that removes a whole second pack from every return.
Do I need a tear strip?
It turns unboxing into five seconds and stops knife damage to the contents. It costs a little per box.
How do I stop the contents moving?
Fit, not padding. Size the box to the product with room for void fill on all six sides.
Can you match my brand color on kraft?
Not accurately — kraft mutes everything. A white underbase fixes it and adds a pass, or start from a white liner.
Do mailers arrive assembled?
No, and that is the point. They ship flat and fold up by hand in seconds.
How fast can I reorder?
Faster and cheaper than the first run, because the tooling already exists. Ask us for a date with the quote.
E-flute or B-flute?
E-flute up to about two kilos and where print quality matters. B-flute above that, or for anything breakable.
Is inside print expensive?
On litho-laminated boxes, barely — one extra pass. On flexo-printed corrugated it means a second setup and rarely pays below a few thousand units.
Can I get white boxes without printing?
Yes. White-top kraft with no print is the cheapest way to look deliberate, and a printed sticker gives you brand without a print run.
How do I stop boxes bursting in transit?
Usually the closure, not the board. Roll-end tuck-front holds well for light goods; anything heavy wants full-flap and tape.
Do you supply them flat?
Always. They fold in a few seconds and flat-packed boxes cost a fraction to ship and store.
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