What Are Custom Mailer Boxes?
Custom mailer boxes are printed corrugated boxes with a hinged lid and a front tuck that closes without tape. Many buyers call them tuck top mailer boxes because the lid folds over and tucks in at the front.
Side dust flaps keep the contents inside, and the double front wall holds the lid shut through sorting machines. That is why a mailer box ships on its own with the label on the lid while a gift box needs an outer carton.
Board thickness and size depend on the product, and our corrugated mailer boxes page lists the common sizes and flutes. With the structure clear you can pick the mailer that fits what you sell.
Which Mailer Box Do You Need?
Pick the mailer by what you ship and how you want it to look, then open that page for sizes and details.
| Mailer page | Choose it when |
|---|---|
| Corrugated Mailer Boxes | You need a different flute, a tear strip or a standard size |
| White Mailer Boxes | You print full color photos or pale brand colors |
| Brown Mailer Boxes | You want a natural kraft look with a one color logo |
| Black Mailer Boxes | You want black that stays dark at every fold |
| Colored Mailer Boxes | You need any other brand color, inside or out |
| Orange Mailer Boxes | Your brand orange needs a Pantone match |
| Blue Mailer Boxes | You print a single blue outside |
| Custom Glossy Mailer Boxes | You want a high shine finish |
| Literature Mailer Boxes | You ship books, catalogs or sales kits flat |
| Custom Subscription Boxes | You send one box to subscribers every month |
| Custom Holiday Mailer Boxes | You ship seasonal gifts and holiday orders |
| Vinyl Record Shipping Boxes | You ship LPs that must not bend |
| 10×13 Poly Mailers | You ship single soft items in a light bag |
| 19×24 Poly Mailers | You ship coats, bedding or large soft orders |
Every page above uses the same minimum, sampling and shipping terms, so you can mix styles in one order. Whatever style you choose the print is what turns it into your box.
How Do You Print Custom Mailer Boxes With Your Logo?
Custom mailer boxes with a logo print in CMYK or Pantone on the outside and the inside, on white, kraft or black board.
Printed mailer boxes look sharpest on a white liner, while a one color logo on kraft keeps costs low. A Pantone spot ink keeps a brand color the same on every reorder, and our guide to CMYK explained shows where process color falls short.
Branded mailers often print a short message inside the lid because that is the part customers film. A matte or aqueous coat protects dark artwork from scuffs in the mail, and the design itself can be tested before you order.
How Do You Design a Mailer Box Before You Order?
You design a mailer box by drawing it at your size in our free dieline generator and checking it in 3D before anything is printed.
The dieline generator turns your length, width and height into a flat layout with cut and fold lines. Our 3D box studio then opens the same box as a mailer box mockup, so you can add artwork and see the lid open.
These tools help with mailer box design ideas too, because you can test a bold outside against a quiet inside in minutes. Once the design works the last detail is how the product sits inside.
Do Custom Mailer Boxes Come With Inserts?
Yes, custom mailer boxes with inserts hold each product in a cut out so nothing moves in transit.
Card inserts suit cosmetics, candles and sets, while EVA foam suits glass and electronics that need cushioning. An insert also lets one box size carry several products, which keeps your stock of boxes simple.
Send the product sizes with your quote request and we draw the insert into the dieline. Ordering is the final step and takes one short form.
How Do You Order Custom Mailer Boxes Wholesale?
Send the product size, the style and the quantity through our quote form and we return a dieline and a price for your custom packaging boxes. Custom mailer boxes wholesale run from $0.80 to $3.90 per box depending on size, board and quantity.
- Minimum order is 100 boxes per size and design and it comes down on rigid, corrugated and larger sizes
- Price breaks arrive at 500 and 1,000 units on one artwork and not across mixed designs
- Production takes 8 to 10 business days for folding carton and 10 to 12 for rigid and wrapped
- A plain sample takes 3 to 5 business days and a printed one takes 7 to 10
- No setup or tooling fees apply because the die and the plates sit inside your unit price
- Shipping is free across the United States on every order we take
Custom mailers for small business start at 100 boxes per size, so a new brand can test one design before a larger run. Test a plain sample with your product before the printed order.
The Customized Boxes