A custom mailer box is a printed, self-locking corrugated box that ships a product and presents it in the same piece of packaging. TBPB makes them to your exact dimensions with no minimum order, so you can order one box for a sample or several thousand for a launch, and if you bring a written quote for the same specs we will beat it under our price-beat guarantee.
How a mailer box is built and how it closes
Most mailer boxes are die-cut from a single sheet of corrugated board. The lid folds over, a front panel tucks under it, and a dust flap keeps the lid from rubbing against whatever sits inside. No tape and no glue gun at the packing bench. That is the whole appeal for small teams: a person can build and fill one in a few seconds.
The board is usually E-flute, a thin corrugation that prints cleanly and still takes a knock in a carrier network. B-flute is thicker and stiffer, and it earns its place when you ship something heavy, like a ceramic mug set or a glass candle. If you are not sure, tell us what goes inside and what it weighs, and we will say which way to go.
Getting the size right
Sizing is where most first orders go wrong. Measure the product itself in three directions: length, width and height. Then decide how much movement you will tolerate. A snug fit looks better on opening, but a loose product with no insert rattles and scuffs in transit. Mailer box dimensions are given as inside measurements, so a product that is 6 inches wide needs a box a touch wider than 6 inches, not exactly 6.
If the product is fragile, plan for an insert. Paper pulp, corrugated and foam all work, and a custom foam insert is the usual choice for electronics, glass and anything with a delicate finish.
Print, finish and what they do to the budget
You can print the outside, the inside, or both. A printed interior is the cheap trick that makes an unboxing feel intentional: the customer lifts the lid and sees your pattern or a thank-you message instead of bare brown board. Outside, your options include full CMYK, a Pantone match for a brand color that has to be exact, and a matte or gloss aqueous coating to protect the ink from scuffing. Soft-touch lamination feels good but shows fingerprints on dark colors, so think about whether your box will be handled a lot before choosing it.
- Corrugated E-flute or B-flute, white or kraft liner
- Custom length, width and height, with inside dimensions confirmed on the dieline
- Print on the outside, the inside, or both
- Pantone matching, aqueous coating, soft-touch lamination, spot UV or foil where the board allows
- Optional inserts, tissue and stickers to complete the unboxing
When a mailer box is the wrong choice
A mailer is not the right answer for everything. Soft goods like T-shirts ship cheaper and lighter in a poly mailer. A very heavy or very tall product wants a different box style entirely, and a premium gift set might look better in a rigid box than in corrugated. If your product is for a gifting occasion, take a look at our gift mailer boxes. If you want a natural, unbleached look and cheaper ink coverage, the kraft mailer boxes are worth a look, and for general online-store shipping our ecommerce boxes cover plain and branded options. The full range sits in the mailer boxes category.
Ready to quote
Send the product dimensions and the quantity you want, even if it is just one, and TBPB will draw the dieline, confirm the inside size and quote it. Artwork can follow once you have approved the dieline.
Frequently asked questions
Is there a minimum order for custom mailer boxes?
No. TBPB has no minimum order, so you can order a single mailer box to test the fit or thousands for a full run. The quote is based on your size, board and print, not on a minimum quantity.
What size mailer box do I need?
Measure your product’s length, width and height, then add a little clearance, usually about an eighth of an inch per side for a tight fit, more if you use an insert. Mailer dimensions are inside measurements, and we confirm them on the dieline before anything is made.
Should I choose E-flute or B-flute?
E-flute is thinner, prints sharper and suits most apparel, cosmetics and small accessories. B-flute is stiffer and handles heavier or more fragile products better. If your item weighs several pounds or has glass in it, lean toward B-flute.
Can I print inside the box as well as outside?
Yes. Inside printing is a common upgrade because it makes opening the box feel designed. You can print a pattern, a message or a logo inside, and we will show you the placement on the dieline first.
Do mailer boxes protect fragile items without an insert?
Not by themselves. A mailer box protects against crushing and general handling, but a loose glass or ceramic item still needs an insert to stop it moving. Pulp, corrugated and foam inserts all work, depending on weight and finish.
How do I get a mailer box quote that beats my current supplier?
Send the dimensions, quantity and a written quote from your current supplier for the same specs. TBPB’s price-beat guarantee means we will beat a matching written quote.
More Custom Mailer Boxes
See the full Custom Mailer Boxes range, or explore related options with no minimum order and our best-price guarantee:
