Mailer box
Subscription boxes
Mailers printed inside and out, so the first thing people see is the inside of the lid.
Corrugated
Mailer box · Corrugated
Custom mailer boxes
Custom mailer boxes are self-locking corrugated boxes, printed with your brand, that go in the mail with nothing around them. We draw each one around your product, from 50 units per design, and production takes 10–12 days from proof approval.
- Over 30 years in print and packaging
- Free structural design
- From 50 units
- Plastic-free options
- Style
- Roll end tuck front
- Board
- E-flute corrugated
- Best for
- Single items, gifts, D2C
- Minimum order
- 50 units
- Typical production window
- 10–12 days
- Paper-first materials
- 100% recyclable
- For structural design
- $0
Overview
What is a mailer box?
The box they open is the box you designed, so print the inside of the lid. That's what people see first, and what gets filmed. If your orders are heavy or hold several items, a flap-top shipping box will do the job for less.
A mailer box is a corrugated box with a hinged lid that tucks into the front. The trade name is a roll end tuck front, or RETF. The side walls are folded double, so the box stands up on its own and needs no tape or glue to close.
It ships flat, folds in seconds and opens like a lid. That last part is why direct-to-consumer brands use it: the first thing a customer sees is the inside of the lid, not a strip of tape.
- Lid with tuck flap. Locks into the front panel. Add tear strips or a sticker if you want it tamper-evident.
- Rolled side walls. Two layers of board on each side, which is where the strength comes from.
- Dust flaps. Small flaps on the lid that keep the corners closed.
- Inside print. Optional, and the cheapest way to make the opening feel planned.
Specifications
Custom mailer boxes: specifications
Every box is drawn to your product, so these are the options, not a fixed catalogue. Your specialist confirms the exact spec on the proof.
| Spec | Detail |
|---|---|
| Style | Roll end tuck front (RETF), self-locking. Front tuck, double side walls |
| Board | E-flute corrugated (roughly 1/16 inch per wall). B-flute (roughly 1/8 inch) for heavier products |
| Liner | White or kraft (brown) outside, white or kraft inside |
| Outside, inside, or both. One color to full color | |
| Inserts | Paperboard or corrugated inserts cut to your product |
| Add-ons | Tear strip, thumb notch, die-cut handle hole |
| Size | Drawn to your product |
| Recyclability | 100% recyclable corrugated. Skip plastic lamination to keep it that way |
| Minimum order | 50 units per design |
| Structural design | $0. We draw the dieline around your product |
| Proof | Digital proof on your dieline, checked for bleed, folds and barcodes |
| Production | 10–12 days on most orders, from proof approval. Shipping time is on top |
| Default finish | Aqueous coating on every box. Water-based, and it recycles with the box |
| Point of contact | One packaging specialist, from first sketch to delivery |
Board and build
Which board for a mailer box?
Most mailers are E-flute. The liner color sets how the print looks.
| Board | Looks like | Best for |
|---|---|---|
| White E-flute | Bright. Takes full-color print cleanly | Photos, pale brand colors, printed insides |
| Kraft E-flute | Brown and natural. Ink prints darker | One or two strong ink colors |
| White outside, kraft inside | White box that opens onto brown | Bright outside print with a plain inside |
| B-flute | Thicker wall, slightly softer print | Heavier products such as bottles or candles in glass |
Pale pink on kraft prints as beige, because the brown shows through the ink. If your brand color is light, use a white liner. Custom kraft boxes goes through which inks hold up on brown board.
Compare
Mailer box, shipping box or folding carton?
Three boxes people mix up. They do different jobs.
| Mailer box | Shipping box | Folding carton | |
|---|---|---|---|
| Goes in the mail on its own | Yes | Yes | No. Too thin |
| Closes with | Tuck lid | Tape | Tuck flaps |
| Opening | Lifts like a lid | Cut the tape | Pull the tuck |
| Best for | Single items, subscriptions | Heavy or mixed orders | Retail shelves |
Our rule: if the box goes in the mail on its own, you need a mailer. If it sits on a shelf, you need a carton. A mailer on a shelf looks like it's waiting to be shipped, and a carton in a delivery truck gets crushed. For heavier orders, see custom shipping boxes.
Sizing
Sizing a mailer box
Mailer sizes refer to the inside, written length x width x depth. Length and width are the opening, depth is how tall the box stands. Send your product's exact size, plus anything else that goes in: tissue, a card, an insert.
Size matters for postage as well as fit. UPS bills on dimensional weight when it's higher than the actual weight: length x width x height divided by 139 on daily rates, per its shipping dimensions and weight guide. A shallow mailer drawn tight to the product keeps that number down.
Don't add clearance yourself. Structural design is $0 and we add it on the dieline. If you're not sure which side is which, read how to measure a box.
Who uses custom mailer boxes
- Direct-to-consumer brands. The box is the first thing customers touch.
- Subscription boxes. See custom subscription boxes for monthly runs.
- Clothing. Shallow mailers for folded garments. See custom apparel boxes.
- Beauty and skincare. One mailer with an insert holding a few bottles in place.
Finishes
One finish, on the logo.
Most mailer boxes need one finish, not four. Aqueous coating goes on every box by default. Add one more only where people will notice it.
Aqueous coating
Default on every box. Protects the print through the mail.
Foil stamping
One logo on the lid. Catches light on the doorstep.
Debossing
Pressed in, no ink. Works well on kraft liners.
Soft-touch
Velvet feel, but it adds plastic. Skip it if you need plastic-free.
Quote
Get a quote for custom mailer boxes
One measurement and a quantity is enough to start. Your specialist replies with a structure, so you can see the box before you commit to anything.
How it works
Four steps, one person.
The specialist who picks up your first email stays with the project until the boxes arrive.
Step 01
Tell us what you're packing
Send the product dimensions, how it ships and how many you need. A photo on a ruler is enough to start.
Step 02
We draw the structure
Your packaging specialist builds the dieline around your product. Structural design is free.
Step 03
You approve the proof
Drop your artwork onto the dieline. We check bleed, folds and barcodes, and send a digital proof.
Step 04
We make and ship
Production takes 10–12 days on most orders. Boxes ship flat, packed in cartons, to your door.
FAQ
Custom mailer boxes: questions.
What is the minimum order for custom mailer boxes?
50 units per design. That's enough to test a box with real customers before a bigger run.
Do custom mailer boxes need tape?
No. The lid tucks into the front and locks. Many brands add a sticker or a tear strip so customers can see it hasn't been opened.
Can you print the inside of a mailer box?
Yes, inside, outside or both. The inside of the lid is what people see first when they open it, so it's usually the best place for a message.
Are mailer boxes strong enough to ship without another box?
Yes, that's what they're made for. E-flute suits most products. For heavier items your specialist will suggest B-flute or an insert.
What's the difference between a mailer box and a shipping box?
A mailer has a self-locking lid and opens like a box lid. A shipping box is a flap-top carton sealed with tape. Mailers suit single items and unboxing; shipping boxes suit heavy or mixed orders.
How long do custom mailer boxes take?
10–12 days on most orders, counted from proof approval. Shipping time is on top.
Honest fit
When not to hire us.
Your box sits on a shelf
A mailer on a retail shelf looks like it's waiting to be shipped. Use a folding carton for retail and keep the mailer for the mail.
You need fewer than 50 boxes
Our minimum is 50 units. For 10 or 20, a stock box with a printed sticker will cost you less.
You need boxes next week
Production runs 10–12 days before shipping. If your launch is sooner, buy stock boxes now and switch to custom for the next run.
You want plain brown boxes
If nothing gets printed, a stock box supplier is cheaper and faster. We're worth it once the box carries your brand.
What goes in your mailer?
Send the product size, or a photo of it on a ruler, and how many you need. We'll come back with a structure and a proof.
Start a projectPopular boxes
Related boxes.
Mailer box
Apparel boxes
Shallow mailers sized for folded garments. Tissue and a sticker finish the job.
Corrugated
Shipping box
Printed shipping boxes
Standard flap-top cartons with your logo on the outside. Built for heavier orders.
Corrugated
Folding carton
Folding cartons
Tuck-end cartons for the shelf. Ship flat, fold in seconds, print edge to edge.
Paperboard