Custom mailer boxes are durable, self-locking packaging solutions designed for shipping and brand presentation. They provide secure product protection, easy assembly, and strong branding for e-commerce and subscription businesses.
Custom mailer boxes are corrugated packaging boxes designed with interlocking flaps that close securely without the need for tape. These boxes are widely used for shipping products directly to customers while maintaining a clean, branded unboxing experience.
They are especially popular among e-commerce brands, subscription services, and online retailers.
Mailer boxes are built to withstand shipping and handling. Key structural benefits include:
Self-locking design for secure closure
Strong corrugated construction for impact resistance
Flat shipping and easy assembly
Protection against crushing during transit
These features make mailer boxes reliable for both domestic and international shipping.
Custom mailer boxes are manufactured using high-quality corrugated materials, including:
E-flute for lightweight and premium packaging
B-flute for added strength and durability
Kraft corrugated board for eco-friendly packaging
Recyclable and sustainable material options
Material selection depends on product weight and shipping requirements.
Mailer boxes offer full customization to enhance brand identity and customer experience. Options include:
Full-color printing inside and outside
Matte, gloss, or soft-touch finishes
Custom box sizes and structural styles
Branded messages for unboxing experience
Inserts, dividers, and protective add-ons
These boxes are commonly used for:
E-commerce product shipping
Subscription and monthly boxes
Apparel and accessories packaging
Cosmetics and beauty products
Promotional and influencer kits
Their versatility makes them suitable for a wide range of industries.
Custom mailer boxes help brands deliver products safely while creating a memorable unboxing moment. They combine protection, branding, and convenience in one packaging solution.
If you want packaging that supports shipping efficiency and brand growth, custom mailer boxes are an excellent choice.
Choose a packaging style for your custom boxes, start designing with us, and get your boxes with the most advanced printing techniques.
Materials
Coating Options
Printing Methods
Color Options
AddOns
SBS C1S
Premium-grade bleached white paperboard with one-sided coating for high-quality color printing and finishes.
SBS C2S
Premium-grade white art card coated on both sides for high-quality printing and finishing options.
Kraft Card
Brown Kraft Card is made of virgin and recycled pulp and coated on both sides for printing.
Textured Card
Textured paper stock is primarily used to wrap rigid boxes and is of the highest grade.
Brown flute
An uncoated and unbleached linerboard composed of recycled and virgin paper pulp.
White flute
White linerboard with bleached white coating for high-quality printing and finishes.
E-flute
A flat surface with a thickness level of 1/16" allows high-quality printing options.
B-flute
A slightly thicker surface with a thickness level of 1/8" for die-cutting and high-quality printing.
Grey Chipboard
Grey Chipboard made of recyclable paper pulp, which is used in the construction of rigid boxes.
Duplex Chipboard
Duplex Chipboard made of recycled pulp paper with a white surface for high-quality printing.
Kraft Chipboard
Brown Kraft Chipboard is made of virgin and recycled pulp and coated on both sides for printing.
Aqueous
Water-based coating offers environmental friendliness and fast drying.
Gloss
A highly reflective coating gives a shiny, polished appearance.
Matte
Diffused, non-reflective coating offering a subdued, elegant look.
Soft Touch
This creates a velvety, tactile feel, often used for a luxurious effect.
UV Coating
Cured with ultraviolet light, provides instant drying, durable, and excellent chemical resistance.
Varnish
Clear, hard coating that enhances protection and adds a glossy or matte finish.
Digital Print
A plate-less digital printing method where designs are transferred electronically. Cost-effective for short runs and quick turnaround.
Offset Print
High-quality printing method utilizing plates and a rubber blanket to transfer designs onto paper; ideal for large-volume production.
Screen Print
A printing method where ink is pushed through a mesh stencil onto a substrate. Ideal for bold graphics and thick ink deposits on diverse materials.
UV Print
Fast-drying printing method using ultraviolet light to cure inks, resulting in a durable, glossy finish on various substrates.
CMYK
A standard four-color printing process (Cyan, Magenta, Yellow, Black) is used to create a wide color spectrum.
Pantone
A standardized color-matching system ensures accurate color reproduction across different printers and materials.
UV Ink
Instantly cured under UV light, it is ideal for printing on non-porous materials, with enhanced durability and vibrancy (can include metallic effects).
Soy Ink
Eco-friendly ink alternative made from soybeans, offering brighter colors and improved biodegradability.
Blind UV
Creates a subtle, textured UV effect without added gloss.
Debossing
Creates a depressed, indented effect on paper or cardstock.
Embossing
Creates a raised, textured effect on paper or cardstock.
Foiling
Adds a shiny, metallic finish to specific areas of a design.
Spot UV
Applies a glossy, clear coating to highlight specific areas of a design.
Window Patching
Incorporates a clear plastic window into packaging or print materials.
To order custom boxes, fill out the quotation form. Let us know the material and finishing options you'd like for your boxes.
Our design team will review your submitted artwork. If any changes are needed, they'll let you know and guide you on file formats and resolution.
Several factors can affect the pricing of your custom boxes, including the material you choose, add-ons, finishing options, and color printing.
Yes, absolutely! Mailer boxes are made of corrugated cardboard and come in two different thicknesses (E-flute 1/16" and B-flute 1/8") to suit your product type. Both options are perfect for shipping.
Yes. You can request a 3D mockup or 2D proof of your box from our design support team. Once you approve the digital proof, we will start the manufacturing process.
Choose a packaging style for your custom boxes, start designing with us, and get your boxes with the most advanced printing techniques.
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