Mailer Boxes - Custom Corrugated Mailing Boxes
Good news! We now offer Rush Production on custom box orders.
Take your mailers to the next level with
Custom Inserts
Our dedicated US-based packaging team will work with you throughout the process to design and order the perfect inserts for your mailers.
How to Order
Need a Sample?
No problem! We can make you a single custom box with your own design and dimensions.
To order, set the quantity to “1 Sample” at the top of this page.
Create a memorable unboxing experience.
Deliver your customer's e-commerce orders, subscription boxes, literature mailer boxes and promotional kits in high-quality colored mailer boxes. Made of durable corrugated cardboard, every order is protected as it ships to your customer. They'll be excited to reveal your items in their next unboxing video.
Our printing services let you design your own mailers—customize every detail, from choosing a custom size to executing the most intricate design.
Fold and Flap. As Easy as That.
The Roll End Tuck Front box is designed for easy and quick assembly with great protection. It comes scored to indicate which lines are for folding.
Send a Plethora of Products
Custom mailer boxes are used to deliver both purchases and promotional items:
- E-commerce orders
- Subscription boxes
- Promotional kits
- School boxes
Subscription boxes treat customers to a curated experience of your product. Some of the companies that commonly order these are:
- Beauty & makeup
- Wine & food samples
- Clothing & retail
Shipped to You Right on Time
Custom mailer boxes take only 10 - 15 business days to produce before they are shipped.
Samples are shipped within 3 - 5 business days.
Size. Style. Material. It's all here, and more.
Custom Mailer Box Sizes
We produce your custom mailers in the exact size you need within the following ranges:
- Length: 3" – 25".
- Width: 2" – 25".
- Depth: 1" – 15".
The sizes we show correspond to the interior dimensions. Depending on your box's application, you may want to add some clearance to each side to make sure your products fit perfectly.
Sustainable & Durable
Our custom mailer boxes are made of sustainable, recyclable, and sturdy corrugated cardboard. No extra packaging needed to send your corrugated mailers.
Material Options
To start customizing your printed corrugated box, choose from the following options:
Standard White Corrugated Cardboard
- Popular, economical option
- Made of sturdy, sustainable material
- Uncoated finish
Premium White Corrugated Cardboard
- Smooth surface with a feel
- Clay-coated for a whiter brighter finish
- Best for luxury brands, gift boxes and promotional kits
- Select “Premium With Glossy Ink” for a high-gloss UV finish on printed areas
Kraft (Brown) Corrugated Cardboard
HD Print
Material thickness
We automatically select a material thickness that works best for your box dimensions. If you require a specific thickness, please contact us.
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How to Assemble Your Mailer Box
Custom Mailer Box FAQ
We use the QR code to speed up the production of your custom boxes. It also helps us track your order better. Don’t worry, the QR code won’t affect the design since it’s not visible once the box is assembled.
Once your artwork is approved for production, it takes 10-15 business days to produce your boxes. Transit-time will be 2-5 business days from there depending on the shipping method you select at checkout. If you need the mailer boxes sooner, there's a rushed production schedule between 6 to 8 business days.
Sample orders of 1 box will ship within 3 - 5 business days. Read more about our production and turnaround times.
If you’re wondering how to make a mailer box, our online design tool is simple to use and lets you create a custom box design.
If you’d like to receive a dieline template based on your box specs, place your order first, and we will create one for you.
Select kraft corrugated cardboard if you want a rustic, natural-looking brown color to complement your design. This material works best with darker color palettes.
White corrugated cardboard can be used for a variety of designs. Both dark and light colors print well on white material. If you are in doubt, this material is your best bet.
We can arrange for a kraft-like texture to appear on the premium or standard white cardboard. You can contact our customer service for more information. Otherwise, white ink will appear brown if you select kraft as your corrugated cardboard color.
Yes, you can print colors and designs on the inside and outside areas of the mailer box. Full-color printing is also available on only one side of the box, if you prefer.
Depending on the specifications of your project, we can offer different solutions to achieve white Ink on kraft appearance. You can contact our customer service for more information.
With the box open toward you, here's how to get the correct measurements for the inside of the box:
- The length is measured from the left to right side of the box.
- The width is measured from the front to the back of the box.
- The depth is measured from the top to the bottom of the box.
Customer Questions
While you are on the product page, you can actually configure your own size or select from the standard sizes. If you need help navigating, please give us a call as our support teams are available 24/7 on weekdays and during office hours on weekends.
In terms of pricing, the Kraft Brown material is the same as the Standard White with Matte Ink. The price would be the same wherther you use one color or full color. It is only when you select the Premium White with Satin Ink and Premium White with Glossy Ink that the materials become costlier.
Yes, you certainly can order one piece first. After creating an account online, you can create an unpaid order selecting "1" in the Quantity Pulldown. You will receive a template of the dieline a few minutes later to guide you in your design. You can then upload the finished design and get a free proof. If everything is ok, you may finalize the order and receive the item in 12-15 business days. If you encounter any issue or have additional questions, please give us a call.
We use digital printers from HP and Inca using inkjet technology to print our Mailer Boxes.
For the Mailer Boxes, when you select Premium White with Glossy Ink material, we will use UV ink that can highlight your designs. This is not true Spot UV but the finish is pretty elegant. We need to see your design as it is not always effective to use Black on Black so there needs to be some color contrast to be done so the design can be seen well. We can do Spot UV if you select Product Boxes and choose one of the Cardstock options for the material. This however, will be a custom job. You will need to call in and speak to a Custom representative to get a quote.
1,000,000+ business professionals trust us with their printing.
Excellent customer service anytime you need it.
The box you want. The way you want. Professional results guaranteed.
A box specialist will give your artwork a hands-on review.
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