The mailer box is what turned plain brown shipping into a brand experience. It is a one piece corrugated box with a roll end front that folds and locks without tape, so it protects a folded garment, a set of products, or a subscription haul without needing an outer carton. For a direct to consumer brand, it is usually the single most important package you buy, because it is the first physical thing a customer touches from you.
What makes a mailer box work is the fit and the board. Size it snug to the product so nothing rattles, and pick the flute for the job: E flute, about one sixteenth inch, prints fine detail and small type crisply for lighter goods, while B flute, about one eighth inch, adds rigidity for heavier or fragile items. Kraft board reads natural and hides scuffs, white gives you a bright canvas for full color print, and the whole interior prints too, so the unboxing can carry a message, a pattern, or a thank you.
Add a fitted insert to hold the product proud and centered, tissue and a sticker for the reveal, and you have a package customers photograph and post. We make custom mailer boxes to your exact dimensions with no minimum order, so a new brand can order 50 to test a design and a large brand can reorder at volume, at the best price. Send us the product dimensions and your monthly count and we will size the box and quote it.
Mailer box FAQ
What is a mailer box used for?
Shipping direct to consumer products without an outer carton: apparel, cosmetics, subscription boxes, gift sets, and small goods. The roll end front locks without tape, it prints edge to edge inside and out, and it protects the product through the mail while doubling as branded packaging.
What is the difference between E flute and B flute mailer boxes?
E flute is about one sixteenth inch thick and takes fine print and small type best, ideal for lighter products. B flute is about one eighth inch and adds rigidity and protection for heavier or more fragile items. Many brands choose E flute for the print quality.
Do mailer boxes need tape?
No. A mailer box has a roll end front with tuck flaps that fold and lock the box shut without tape, which is faster to pack and gives a cleaner look. A tape strip or a sticker seal can be added if you want extra security.
Is there a minimum order for custom mailer boxes?
No. We make custom mailer boxes with no minimum order, so you can order a small run to test a size and design before scaling to volume, at the best price.
