Custom mailer boxes are the go-to packaging for online brands. They ship safely through the post, lock shut without tape, and open like a gift, which makes them perfect for e-commerce orders, subscription boxes and influencer kits.
We make custom printed mailer boxes from sturdy E-flute or B-flute corrugated board, sized to your products and printed on the outside, the inside or both. Add a tissue-wrapped insert, a thank-you message under the lid or a tear strip, and every delivery becomes part of your brand experience.
Mailer boxes ship flat, fold in seconds and are fully recyclable, so they are as practical for your packing team as they are impressive for your customers.
Key features
- Self-locking roll-end tuck front design
- E-flute and B-flute corrugated board
- Print outside, inside or both
- Made to your exact size
- Recyclable and ships flat
Why choose custom mailer boxes?
An unboxing worth sharing
Printed interiors, inserts and messages turn a delivery into a moment customers film and share, giving you free reach on social media.
Strong enough to ship on their own
Corrugated mailer boxes protect products in transit and can usually be sent without an outer shipping carton, saving time and material.
Fast to pack
The self-locking design needs no tape or glue. Your team folds, fills and closes each box in seconds.
Choosing the right mailer box size
Measure the inside space your products need, then allow a little room for tissue or an insert. A snug fit looks more premium and stops items moving in transit. If you ship several products, we can design one mailer with an insert that holds each item in place, or a set of sizes that cover your range.
Send us your product dimensions or a photo with a ruler, and we will recommend the right size and board strength for your shipping method.
Styles of custom mailer boxes we make
Every style below can be made to your exact size and printed with your artwork. Not sure which suits your product? Tell us what you are packing and we will recommend the best option.
- Roll-end tuck front mailers: the classic e-commerce mailer with a locking front panel.
- Mailers with inserts: die-cut cardboard inserts for bottles, jars or kits.
- Kraft mailer boxes: natural brown board for an eco look.
- White mailer boxes: bright white board for vivid full-colour print.
- Mailers with tear strips: easy-open strips for subscriptions and returns.
- Double-sided printed mailers: full artwork outside and a surprise inside.
Materials for custom mailer boxes
Mailer boxes are made from corrugated board. E-flute is thin and smooth, ideal for printing and lighter products; B-flute is thicker and gives more cushioning for heavier or fragile items.
- E-flute corrugated for most e-commerce orders
- B-flute for heavier products
- White, kraft or black outer liners
- Recycled content options
Printing, finishes and add-ons
Printing is where your custom mailer boxes start working for your brand. We print in full colour CMYK or exact Pantone shades, on the outside, the inside or both, and add finishes that customers notice the moment they pick the box up.
- Full-colour CMYK outside and inside
- One-colour logo print on kraft for a budget-friendly look
- Matte or gloss lamination
- Foil logos and spot UV
- Printed inserts and tissue paper
- Branded stickers and tape
Custom mailer boxes wholesale pricing
The price of custom mailer boxes depends on a few simple factors, and knowing them helps you get the best value from your budget:
- Size and style: larger boxes and complex structures use more board and set-up.
- Material: paperboard costs less than corrugated, and corrugated less than rigid board.
- Printed sides: outside-only printing is the most economical; inside printing adds impact for a little more.
- Finishes: foil, embossing and soft-touch add a premium feel and a small cost per box.
- Quantity: the unit price drops as the order grows, so wholesale runs give the best value.
Tip: keep one structure across several products and change only the artwork, and you can order custom mailer boxes in larger combined runs at a lower unit price. Request a free quote and we will suggest ways to reduce cost without losing quality.
Sustainable custom mailer boxes
More customers now check whether packaging can be recycled before they buy. We can make your custom mailer boxes from recyclable and recycled-content board, print with water-based or soy-based inks, swap plastic windows for open or plant-based film, and right-size every box so it uses less material and less void fill. Add a small recycling symbol and message to show customers you care.
Artwork tips for custom mailer boxes
- Design on the dieline we send, with 3 mm (1/8 inch) bleed past every cut edge.
- Keep text and logos at least 3 mm inside folds and cut lines.
- Use 300 DPI images and CMYK colours, or Pantone references for exact brand colours.
- Send logos as vector files and convert fonts to outlines.
- Put the product name and main benefit on the front panel, and barcodes and legal text on the back or base.
Who uses custom mailer boxes?
Custom mailer boxes are used by businesses of every size, from start-ups testing a first product to established brands ordering in bulk:
- E-commerce and online stores
- Subscription boxes
- PR and influencer kits
- Corporate gifting
- Meal kits and snack boxes
- Apparel and accessories
How to order custom mailer boxes
- Request a quote: send us your box size, quantity, material and finish, or simply describe your product.
- Free design and 3D mockup: we prepare the dieline, help with artwork and show you a 3D preview.
- Approve your proof: check every panel, colour and line of text. Nothing is printed until you say yes.
- Production and quality checks: your boxes are printed, finished, die-cut and inspected. Timings are confirmed in your quote.
- Delivery: boxes arrive flat-packed to save space and shipping cost, ready to assemble.
Why order custom mailer boxes from Custom Boxes Peak?
We make every order to measure, so you never pay for a stock size that does not fit. Free design help, a free 3D mockup and a free digital proof come with every order of custom mailer boxes, and low minimums mean you can start small and scale up as your brand grows. Our team checks every file for bleed, resolution and colour before printing, so the boxes you receive look exactly like the proof you approved.
