A custom mailer box is where a direct to consumer brand turns shipping from a cost into a marketing channel. Instead of a plain box, every parcel arrives printed with your brand, inside and out, and locks shut without tape thanks to the roll end front. It is the package that greets the customer at the door, so it is worth designing as carefully as the product.
Custom means the box is built around your product and your brand. Size it snug so nothing rattles, pick E flute for crisp print or B flute for strength, choose kraft or white board, and print the exterior, the interior, or both. Add a fitted insert to hold the product proud, a printed message on the inside lid, and finishes like a matte laminate or a soft touch coat. The whole box becomes the unboxing.
We make custom mailer boxes to your exact dimensions with no minimum order, so a new brand can test a design on 50 units and scale when it sells, at the best price. Send us the product size and your monthly volume and we will spec the box and quote it.
What a custom mailer box has to do
A mailer box is the workhorse of ecommerce, so it has two jobs. It has to survive the carrier without a shipping box around it, and it has to make the open feel like a brand moment. The classic build is a roll end tuck front carton in corrugated board with side wings that lock, which ships flat, folds without tape, and protects the product on the way.
Board and strength
The choice that matters most is the flute. E flute, about a sixteenth of an inch, keeps the surface smooth for crisp printing and suits lighter goods. B flute, about an eighth of an inch, adds stiffness and cushioning for heavier or fragile items. For most direct to consumer products E flute is the sweet spot, and we help you pick based on weight and what is inside.
Sizes and inserts
The fastest way to cheapen a nice product is a box that is too big. We build the mailer to the product with a snug internal fit, and add a die cut insert, a foam layer, or molded pulp when the item needs to be held in place. Send the product or its dimensions and we send a free dieline, a 3D mockup, and a physical sample before you order.
Print and finish
Mailers print inside and out, so the inside panel is prime space for a thank you, a discount code, or a pattern that makes the unboxing pop. Outside you can go full color, a clean one color on kraft, or add soft touch lamination, spot gloss, or foil on the logo. All of it is offset or digital based on your run size.
Ordering, samples, and price
There is no minimum order, so you can start with a small batch and scale as you grow. Design is free, samples are free, and we price match any comparable written quote. Send your product size, quantity, and the look you want, and we come back with a dieline, a mockup, and a price the same day.
Custom mailer box FAQ
What is a custom mailer box?
A corrugated mailer box built to your exact size and printed with your brand inside and out. The roll end front locks without tape, and it ships direct to consumer products without an outer carton while doubling as a branded unboxing experience.
Can I print the inside of a mailer box?
Yes. The interior prints just like the exterior, so you can add a pattern, a message, or a thank you that customers see when they open the box. Printed interiors are a big part of a memorable unboxing.
What size custom mailer box do I need?
Size it snug to the product so nothing shifts in transit. Send us the product dimensions and we will build the box to fit, which also cuts void fill and dimensional weight charges.
Is there a minimum order for custom mailer boxes?
No. We make custom mailer boxes with no minimum order, so you can test a design on a small run before scaling to volume, at the best price.
More Mailer Boxes
See the full Mailer Boxes range, or explore related options with no minimum order and our best-price guarantee:
