A custom mailer box is a one-piece shipping box with a hinged lid and a front tuck that holds it closed, printed so the unboxing starts the moment it arrives. TBPB makes them to your product dimensions with no minimum order, and we will beat a written quote for the same specs.
Why a mailer, not a shipping carton
A regular shipping carton gets the product there. A mailer does that and gets opened. It folds up from flat without tape, closes with a tuck, and prints on the inside as well as the outside, which is where many brands put a thank-you note or a product story. Subscription boxes, apparel, candles, skincare sets and small electronics suit it. If you ship items with a gift presentation, a mailer holds a rigid box or a bagged product inside it, and our white rigid boxes are a common inner pack.
Board and strength
Most mailers are corrugated, with E-flute being the common choice because it is thin, prints well and still stands up to parcel handling. B-flute is thicker and takes more crush. For very light items, a paperboard mailer saves weight, but it protects less. The right choice depends on product weight and how it travels, not on how it looks. Heavy glass, for instance, needs a thicker board plus an insert. Ask us about the board you should use when you tell us the product weight and the shipping method.
Sizing the mailer
Size from the inside, not the outside. Measure the product and any insert or tissue, then add a little room so the box closes without bulging. A loose product slides and gets damaged, while a tight one rips the tuck when closed. Measure to the third dimension too: the depth you need includes the lid return, so a thick product pushes the lid up. Our custom foam inserts fix the product in place if you ship fragile items. The sibling TBPB mailer boxes page shows more variations.
Think about the packing step too. A mailer that takes thirty seconds to fold and fill gets used, while one that fights the person packing it ends up in a corner. The tuck-in front means no tape or glue, so a single person can pack at a table. If you fill at volume, mention it when you order so we can talk about the lock style and score depth, because those decide how smoothly the lid closes after the hundredth box.
Last point, on cost. Printing every surface is not always the smart move. A plain kraft exterior with a one-color logo and a bold full-color interior often looks better than a fully printed outside and does more with less ink. Start with the surface your customer sees first, then decide whether the rest earns its place.
- One-piece corrugated mailer with a tuck-in front
- E-flute or B-flute, or paperboard for light items
- Outside and inside printing, CMYK or Pantone
- Kraft or white exterior
- Optional insert for fragile items
Print, finish and honest limits
Printing on corrugated is good for graphics and solid colors, but very fine detail on brown kraft is softer than on white paperboard. If your brand depends on subtle gradients, choose a white exterior. Finishes are limited compared with rigid boxes, so keep the design clean and let one large color field carry the brand. A mailer is not waterproof. It will take a light drizzle, not a puddle, so ship in poly bags if weather is a risk. Browse the whole mailer boxes category for related builds.
Next step: send your product dimensions, weight and a quantity, even one. We draw the dieline and quote it.
Frequently asked questions
What is a custom mailer box?
A custom mailer box is a one-piece corrugated or paperboard box with a hinged lid and a front tuck. It ships flat, assembles without tape, and is printed on the outside and often the inside, so it serves as both shipping carton and brand experience.
Is there a minimum order for mailer boxes?
No. TBPB has no minimum order, so you can order a single mailer to test the fit and print, or thousands for regular shipments. The sizes and print options are the same at every quantity.
Which flute is best for a mailer box?
E-flute is the common choice because it is thin, prints cleanly and still handles parcel shipping. B-flute is thicker and takes more crush, which suits heavier items. Tell us the product weight and how you ship, and we advise on board.
How do I size a mailer box?
Measure the product, plus any insert or tissue, and size from the inside dimensions. Leave a small amount of clearance so the lid closes flat. Include the lid return in the depth. Send us the numbers and we draw the dieline.
Can I print inside the mailer?
Yes. Inside printing is a common option and is often used for a thank-you message, a product story or care instructions. It gives the customer something to read the moment the lid opens, and it costs you nothing in shipping weight.
Are mailer boxes waterproof?
No. Corrugated board resists light moisture for a short time but is not waterproof. If your shipments face rain or long transit, add a poly outer bag. Do not rely on the box alone in wet conditions.
More Custom Mailer Boxes
See the full Custom Mailer Boxes range, or explore related options with no minimum order and our best-price guarantee:
