Mailer Boxes
Custom Mailer Boxes
Branded corrugated mailers built around your product instead of the nearest stock size. Printed inside and out, proofed before anything runs, and shipped to your US address.
Built around your product, not a stock catalog size.
A mailer box is the one-piece corrugated box most ecommerce brands ship in. It folds and tucks closed without tape, and the inside is as printable as the outside, which is why it does more brand work per dollar than almost any other format. Your customer handles it before they handle your product.
We build mailers to your product’s real measurements rather than rounding up to whatever is already on a shelf. That usually means less void fill to buy, a lower dimensional weight, and a box that does not rattle on the way. Send the product dimensions, or just photos and a rough idea, and we come back with a structure recommendation, a dieline and a delivered price.
Where it works best
Ecommerce shipping
Sized to the product, so there is less void fill to buy, less movement in transit and less damage to replace.
Subscription boxes
One repeatable structure you reorder, with print that can change cycle to cycle without a new dieline.
Apparel and accessories
Shallow depths, soft-touch finishes and printed interiors, where the box is part of how the garment presents.
Beauty and skincare
Fitted inserts that hold bottles upright and keep pumps, droppers and caps from taking a knock.
Influencer and PR kits
Short runs where the unboxing is the whole point and the box has to photograph well.
Electronics and hardware
Heavier flutes and insert support, where weight and impact resistance matter more than shelf appeal.
Specifications
Everything below is agreed with you before we proof. If something in your spec will not print or ship well, we say so at quote stage rather than after production.
| Box style | Roll-end tuck-front and roll-end tuck-top one-piece mailers, self-locking, no tape required. Other structures on request. |
|---|---|
| Board | E-flute (roughly 1.5 mm) for the smoothest print surface, or B-flute (roughly 3 mm) where more crush resistance matters. Double wall on request for heavier items. |
| Stock | Natural kraft, white outside with kraft inside, or white on both sides. |
| Printing | Outside, inside, or both. Full-colour CMYK plus Pantone spot matching. |
| Finishes | Matte or gloss lamination, soft-touch, spot UV, foil stamping, embossing and debossing. |
| Sizes | Made to your internal length, width and depth. We confirm the practical limits for your chosen board and finish before proofing. |
| Inserts | Corrugated, folded card or foam inserts sized to hold the product in place, quoted as part of the same order. |
| Minimums | Confirmed in your quote. They move with board, size, print method and finish, and we will tell you honestly if a quantity is not workable for the spec you want. |
| Artwork | Send print-ready files, or send a logo and a reference and we supply the dieline and artwork guidance as part of the job. |
| Lead time | Confirmed in your quote. It depends on structure, quantity and finish, so we give you a realistic window rather than a fixed promise. |
| Production | Made with our trusted partner facilities in Pakistan, quality checked before dispatch. |
| Delivery | Shipped to your US address. Freight method and landed cost are confirmed in your quote. |
Choosing a size
Measure the product at its widest points, not its nominal size, then add clearance for whatever is protecting it. Too much space means you buy void fill you did not need and pay dimensional weight on air you are shipping. Too little and the box bulges, the tuck stops closing cleanly and the print distorts at the fold. If you are unsure, send the measurements and we will propose a size and explain why. Background reading: mailer box vs shipping box, what custom mailer boxes cost, and our small business packaging guide.
Questions we get asked
Minimums are confirmed in your quote. They move with board, size, print method and finish, so a one-colour kraft mailer behaves very differently from a soft-touch laminated white mailer with foil. Tell us the quantity you actually want and we will tell you straight whether it works.
Yes, and it is one of the cheapest ways to make an unboxing feel considered. Inside print can be a full pattern, a single flood colour, or one line of copy where the lid opens. It runs as part of the same job, so it costs far less than adding a printed insert later.
A dieline is the flat template showing where the board is cut and where it folds, with artwork laid out on top. You do not need to supply one. We produce it for your size and send it with guidance on bleed, safe zones and which panels are visible when the box is closed.
Kraft reads warm and natural, is forgiving with light ink coverage and hides scuffs well. White gives accurate colour and genuinely bright whites, which matters if your brand depends on a specific shade or on printed photography. White outside with a kraft interior is a common middle ground.
You approve a digital proof before production, and we can match to Pantone references where colour accuracy matters. A backlit screen and printed corrugated board will never look identical, and kraft shifts colour more than white. If an exact match is critical, ask about a physical sample before the full run.
Your order is produced with our trusted partner facilities in Pakistan, quality checked, then shipped to your US address. Freight method, landed cost and timing are confirmed in your quote.
Other packaging we produce
Shipping Boxes
Product Boxes
Rigid Boxes
Bags and Pouches
Labels, Stickers and Print
Tell us what you are shipping.
Send the product dimensions and a rough quantity. Artwork can come later. You will get a structure recommendation, a delivered price and a realistic timeline.