Mailer Boxes Built to Your Specs
Self-locking mailer boxes shipped flat and assembled in seconds. The unboxing star of the e-commerce world.
Where Mailer Boxes Perform Best
Subscription box brands shipping monthly
Direct to consumer launches that need a memorable unboxing
Apparel and accessories brands shipping under 5 lbs
Mailer Boxes Examples
Material Options
SBS Board
Cosmetics, luxury goods, food packaging
Kraft Paperboard
Eco brands, artisan food, craft positioning
Corrugated E-Flute
Mailer boxes, ecommerce shipping, fragile items
Corrugated B-Flute
Shipping cartons, heavy products, stackable applications
Printing Options Available
Digital
No plates. Fast turnaround.
Best for runs under 500 units and prototypes. No setup fees, variable data possible.
Offset
Sharp, consistent, cost-effective at scale.
Pantone color matching, lowest per-unit cost for runs of 500 or more. CMYK or spot.
Pantone
Exact brand colors, every run.
Solid coated Pantone inks guarantee color consistency from press to press across every order.
Industries That Reach for Mailer Boxes
Brands in these categories rely on mailer boxes to protect product, build recognition, and drive repeat purchase.
Mailer Boxes Questions
Answers to the 7 questions brands ask us most often about mailer boxes.
How much weight can a mailer box hold?+
E-flute mailers hold up to 5 lbs comfortably. B-flute mailers handle 10 to 15 lbs depending on dimensions. For anything heavier, choose a shipping carton.
Do mailer boxes need tape?+
No. The tuck-end and locking flaps hold the box closed. Some brands add a single branded sticker for the unboxing reveal, but tape is never required.
Can I print on the inside of a mailer box?+
Yes. Interior print is one of the most powerful unboxing moves. We offer inside printing at a 30 to 40 percent cost increase over outside-only printing.
What is the smallest mailer box you make?+
Our smallest standard mailer is 4 by 4 by 4 inches. Custom sizes start at 3 by 3 by 1 inch for jewelry and accessories.
Are mailer boxes recyclable?+
Yes. Every mailer box we produce is 100 percent recyclable curbside. Choose our FSC certified kraft or recycled content options for an even smaller footprint.
Can I get a sample before ordering 500 units?+
Yes. We produce a single physical sample of your final design for a flat fee that gets credited toward your first production order.
How long do mailer boxes take to produce?+
Digital print runs ship in 7 to 10 business days. Offset runs ship in 12 to 15 business days. Rush is available for an added fee.
Get a quote for Mailer Boxes
Send your specs. We respond with a detailed quote plus a free 3D mockup within 48 business hours.
- Free 3D design mockup included
- Response within 48 business hours
- No commitment required
- Ships to all 50 US states
Other Styles Worth Considering
Product Boxes
Classic retail packaging. Tuck top or auto-bottom.
Rigid Setup Boxes
Premium unboxing experience. Lid and base construction.
Shipping Cartons
Durable brown kraft cartons for safe shipping.
Guides to help you spec it right
- Strategy 7 min
Custom Box Styles Guide: Which Format to Choose
Eight box formats, one decision. This guide breaks down construction, use cases, and buyer cues for every major custom packaging style.
Read the guide - Cost Savings 10 min
How Much Does Custom Packaging Cost? A 2026 Price Guide
The real cost drivers behind custom boxes: material, print method, quantity, and finishing. Understand the price curve so your quote request comes back exactly right.
Read the guide - Materials 8 min
Rigid Box vs Mailer Box: Which Is Right for Your Brand?
Premium setup boxes or self-locking mailers? Compare cost, protection, unboxing impact, and best-fit products so you choose the right format before you order.
Read the guide