Custom boxes
Custom Mailer Boxes
Custom mailer boxes are corrugated boxes with a fold-down lid and locking front tabs, also called roll end tuck top mailers. They are strong enough to ship on their own and open like a gift box, which makes them the standard for e-commerce and subscription orders.
- Choose size, material and quantity
- Add to cart or send a quote
- Upload your artwork
- Approve your proof and we print
- Delivery: Shipped free to one address
- Artwork check and proof: Free digital proof, usually within 24 hours; nothing prints until you approve it
- Production: 8–12 business days after proof approval, then 3–6 business days in transit
- Reprint or refund: Free if faulty, reported within 30 days of delivery
$89.00 per pack of 100 boxes · $0.89 per box
Total: $89.00 for 100 boxes
Custom Mailer Boxes at a glance
- Box style
- Roll end tuck top mailer with locking front tabs (end-opening mailers have their own page)
- Minimum order
- 100 boxes per size and design
- Unit price
- From $0.89 per box
- Production time
- 8–12 business days after proof approval
- Printing
- One, two or three colors, full color, or unprinted; Pantone or metallic spot colors on request
- Materials
- 32 ECT or 44 ECT single-wall, or 48–61 ECT double-wall (white or kraft outer liner)
- Finishing
- Embossing or debossing, spot UV, hot foil (silver, gold, red, green, blue or holographic), die-cut window
- Ships to
- United States and Canada, with worldwide delivery on request
Custom Mailer Boxes prices by quantity
Starting prices for a standard printed mailer box, full color outside.
| Quantity | Per box | Setup | Pack total |
|---|---|---|---|
| 100 boxes | $0.89 | $0.00 | $89.00 |
| 250 boxes | $0.89 | $0.00 | $222.50 |
| 500 boxes | $0.89 | $0.00 | $445.00 |
| 1,000 boxes | $0.89 | $0.00 | $890.00 |
| 2,000 boxes | $0.89 | $0.00 | $1,780.00 |
| 5,000 boxes | $0.89 | $0.00 | $4,450.00 |
| 10,000 boxes | $0.89 | $0.00 | $8,900.00 |
Why mailers suit online orders
A mailer box does two jobs at once: corrugated board protects the order in the mail, and the lid opens like a gift box when it arrives. There's no outer shipper to throw away and no tape across the artwork, so the first thing your customer sees is your print.
The double-walled front and side flaps also give the box rigid walls without extra inserts, which keeps light products from shifting.
Kraft, white, black or colored mailers
The color of the board's outer liner sets the starting look. Kraft (brown) reads natural and hides scuffs; white makes full-color print brightest; black or a solid printed color feels premium and dramatic. These are versions of the same mailer, so they share this page and are chosen in the quote form.
| Look | How it's made | Best for |
|---|---|---|
| Kraft | Unbleached brown liner, one- or two-color print | Natural, eco-led and handmade brands |
| White | White liner, full-color print | Bright, photographic artwork |
| Black or colored | Solid ink flooded across the box | Premium and fashion brands |
| Heavy-duty | B-flute or double-wall corrugated with a thicker wall | Heavy or fragile products |
| Budget | Kraft liner, one-color logo | High-volume orders where unit cost matters |
Choosing a mailer size
Measure your product and add a small allowance for tissue or an insert; the quote form asks for internal length, width and depth. Avoid oversized boxes: carriers charge by dimensional weight, so a box that is an inch too big in every direction can move an order into a higher postage band.
Designing the unboxing
Think about the order things are seen: the outside print in the mailbox, a message printed inside the lid when it opens, then the product with a hang tag in the same design. Inside printing costs more than outside-only, so many brands keep the outside simple and put the surprise inside.
Full specification
| Box style | Roll end tuck top mailer with locking front tabs (end-opening mailers have their own page) |
|---|---|
| Dimensions (L × W × D) | Made to your product's internal length × width × depth, in inches, millimeters or centimeters |
| Board | 32 ECT or 44 ECT single-wall, or 48–61 ECT double-wall (white or kraft outer liner) |
| Flute | E-flute (about 1/16 in, 1.5 mm), B-flute (about 1/8 in, 3 mm), C-flute (about 5/32 in, 4 mm) or BC double-wall (about 9/32 in, 7 mm) |
| Thickness | E-flute about 1/16 in (1.5 mm) up to BC double-wall about 9/32 in (7 mm) |
| Print method | Digital printing for short runs, where the price per unit stays nearly flat; flexographic or offset litho-lamination usually becomes cheaper from about 1,000–2,500 units. |
| Print colors | One, two or three colors, full color, or unprinted; Pantone or metallic spot colors on request |
| Special colors | Pantone or metallic spot inks on request |
| Printed side | Outside only, or inside and outside |
| Lamination | Gloss, matte or natural (no lamination) |
| Embossing / debossing | Optional embossing (raised) or debossing (pressed in) |
| Spot UV | Optional spot UV on selected areas |
| Hot foil | Optional hot foil in silver, gold, red, green, blue or holographic |
| Die-cut window | Optional die-cut window, open or with clear film |
| Closure | Fold-in front with dust flaps and locking tabs; no tape needed to close, tape or a sticker to seal |
| Insert | Card or corrugated cavity inserts, dividers, molded pulp, and EVA foam or flocked inserts |
| Quantity | 250 to 10,000 per quote request, and more than 10,000 on request; online tiers start at 100 boxes (50 for rigid, magnetic and display boxes) |
| Unit price | From $0.89 per box at the largest quantity; see prices by quantity |
| Turnaround | 8–12 business days after proof approval |
| Sustainability | Corrugated and paperboard boxes go in household paper and cardboard recycling; laminated and foil-finished boxes may not be accepted everywhere. Recycled board is available on request |
| Use case | E-commerce orders, subscription boxes, PR and influencer kits, apparel, cosmetics |
| Industry | E-commerce, subscription, apparel, beauty, food and drink gifts |
Matching packaging
- Matching standard hang tags
Tags printed with the same artwork as the box.
From $0.11 per tag
- Matching clothing tags
Slim garment tags for apparel shipped in the box.
From $0.11 per tag
Related products
- All custom box styles
Compare mailers, cartons, rigid boxes and more.
Questions about custom mailer boxes
Can mailer boxes be shipped without an outer box?
Yes. Mailers are made from corrugated board and are designed to ship on their own. Seal the front with tape or a sticker.
What's the difference between a mailer and a shipping box?
A mailer opens from the top with a hinged lid and locking tabs; a shipping box closes with flaps that are taped. Mailers present better; shipping boxes suit heavier contents.
Can you print inside a mailer box?
Yes. Choose printing on both sides in the quote form.
Which board are mailer boxes made from?
32 ECT or 44 ECT single-wall, or 48–61 ECT double-wall. Thin E-flute board prints sharply and suits most mailers; thicker flutes suit heavy items.
What is the minimum order?
100 boxes per size and design. Quotes cover 250 to 10,000 boxes and more on request.
Do mailers come flat?
Yes. Mailers ship flat and fold into shape without glue or tape.