Custom Mailer Boxes, Printed & Shipped in Bulk
Turn a plain shipping carton into a branded unboxing moment. We print your logo, colors and artwork onto self-locking corrugated mailer boxes — sized to your product, in kraft, white or full color, with no tape required.
Your brand, on every box
Everything you need to know about custom mailer boxes
Custom mailer boxes are one-piece corrugated shipping boxes printed with your logo, brand colors and artwork. They do the same job as a plain brown carton — protecting products in transit — but the self-locking, tape-free design and printable surface turn every shipment into a branded unboxing experience. For ecommerce brands, subscription services, apparel labels, beauty companies and anyone shipping direct to customers, that means a more professional package, better protection, and a shelf-worthy first impression the moment the box arrives.
Because they are made to order, the right specification depends on what you ship and how it should feel out of the mailbox. This guide walks through the board grades and flute profiles that drive strength, the sizes and styles available, how kraft, white and full-color options compare, the print methods and finishes you can add, and how bulk pricing scales with quantity. If you already know what you need, you can request a custom quote at any point.
A branded box works twice — protection and marketing
Plain cartons get recycled and forgotten. A custom mailer box printed with your brand protects the product just as well while turning delivery into a moment customers photograph and share. Whether you are shipping a first order, a monthly subscription, or a VIP gift, custom mailers make your packaging look intentional and unmistakably yours.
Brand experience
Every box becomes an unboxing moment. Print your logo, message and artwork edge to edge, inside and out, so the brand carries all the way to the customer’s door.
Built to protect
Corrugated board with a self-locking, tape-free structure cushions products in transit and holds its shape from warehouse to doorstep.
Made to spec
Pick the size, board grade, material and finish — we match your brand colors and handle bulk runs from small batches to thousands.
From your artwork to your fulfillment center in four steps
Send your artwork
Share your logo (vector preferred), brand colors, product dimensions and the quantity you need.
We design & proof
We build your dieline, lay out the print, match your colors and send a digital proof for review.
You approve
Confirm the proof, size and final quantity. Nothing goes to production until you sign off.
We print & ship
Your boxes are printed, die-cut, glued, quality-checked and shipped flat to your door.
Board grades and mailer box sizes: which do you need?
The flute profile of the corrugated board drives how thin, sleek or protective your mailer feels. Thinner E- and F-flute boards give a smooth, retail-quality print surface for lighter products; heavier B-flute and double-wall boards add rigidity for heavier or fragile items. Here is how the common options compare.
Flute profile thickness
E-flute is the most common choice for mailer boxes — slim, sturdy and smooth to print on. Values are approximate industry ranges.
Typical mailer footprints (longest side)
Every box is cut to your product, so treat these as typical ranges. Aim for a snug fit with room for protective inserts.
| Board grade | Approx. thickness | Best for | Print surface |
|---|---|---|---|
| F-flute | ~0.8 mm | Small, light products; slim retail feel | Very smooth |
| E-flute Popular | ~1.5 mm | Most ecommerce & subscription mailers | Smooth |
| B-flute | ~3.2 mm | Heavier or fragile items needing rigidity | Good |
| EB double-wall | ~4.5 mm | Heavy, bulky or high-value shipments | Good |
Built to survive shipping and keep your brand sharp
Our custom mailers are made from corrugated board — a fluted paper core sandwiched between flat liners that absorbs impact and resists crushing. The one-piece, roll-end tuck design locks closed without tape, folds flat for storage, and pops open in seconds on your packing line. Kraft liners give a natural, recyclable look; white and full-color coated liners give a crisp, high-contrast surface for print.
For heavier or premium products, you can step up to a thicker flute or double-wall board and add protective inserts to keep contents from shifting. You choose the board grade, material and finish that match what you ship and how you want it to feel when the customer opens it — a lightweight apparel mailer and a fragile-goods box are built very differently.
- Corrugated board — cushions and resists crushing in transit
- Self-locking design — tape-free, roll-end tuck closure
- Kraft or white liner — natural or bright print surface
- Recyclable material — curbside-recyclable paper board
- Ships & stores flat — saves space until you pack
- Cured, scuff-resistant print — artwork that survives handling
Make the box unmistakably yours
Full-color printing
Print your logo, artwork and messaging edge to edge in full color, on the outside, the inside, or both.
Material & color
Choose natural kraft, bright white, or full-color coated board to match your brand and unboxing style.
Finishes
Add matte or gloss lamination, soft-touch coating, or spot detail for a premium tactile feel.
Size & style
Made to your product dimensions in mailer, tuck-top and other one-piece styles, from mini to large.
Board grade
Pick E, B or double-wall flute for the right balance of slim profile and shipping protection.
Inserts & extras
Add fitted inserts, tear strips, custom tissue or stickers to complete the unboxing experience.
Kraft, white and full color — and what each signals
Your board and finish set the tone before the box is even opened. Kraft reads natural and eco-conscious; white reads clean and premium; full color reads bold and branded. Common choices:
Need an exact match? We print to your Pantone brand colors on kraft, white or coated board.
How to choose the right custom mailer box
The best mailer comes down to what you ship and how you want it to feel. Use this quick guide to match your product to the right size, board and material.
| What you’re shipping | Recommended size | Board grade | Material / finish |
|---|---|---|---|
| Jewelry, cosmetics, small samples | Mini – small | F / E-flute | White or full color |
| Apparel, accessories, soft goods | Small – medium | E-flute | Kraft or full color |
| Subscription & curated boxes | Small – medium | E-flute | Full color + printed interior |
| Electronics & fragile items | Medium | B-flute | White + fitted insert |
| Heavy, bulky or multi-item orders | Large | EB double-wall | Kraft or white |
Not sure which fits your product? Tell us what you ship and we’ll recommend a spec with your quote.
One box, many brands
How custom mailer box pricing works
Custom mailer boxes are priced per unit, and the per-box price drops as your quantity climbs. Your final quote depends on four things: box size, board grade, print coverage and finishes, and total quantity. Larger runs and simpler artwork bring the unit cost down the most.
Custom mailer box questions, answered
What are custom mailer boxes?
What is the minimum order for custom mailer boxes?
What material are mailer boxes made of?
What board grade should I choose?
What sizes do custom mailer boxes come in?
Kraft vs white vs full color — which is best?
Can I print on the inside of the box?
Do you offer eco-friendly or recyclable mailer boxes?
Can I add inserts, tear strips or other extras?
What artwork format do you need?
Can you match my exact brand colors?
How do I get a quote?
Ready to put your brand on every box?
Tell us your product size, quantity and material — we’ll send back exact pricing, a proof, and a production timeline. Bulk orders welcome.
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