Roll-end tuck top
The classic mailer. Side flaps roll under, front tab tucks in. No tape needed.
Custom mailer boxes — printed corrugated
Custom mailer boxes, printed inside and out.
Self-locking corrugated mailers made to your product's dimensions and printed with your brand — outside, inside, or both. The box a customer opens at home is the one they remember, so it is built as packaging, not as a carton to put packaging in.
- Construction
- Self-locking corrugated
- Outside · inside · both
- Minimum order
- 50 boxes
What a mailer box is
A branded box that survives the journey and opens well.
A custom mailer box is a one-piece corrugated structure — usually a roll-end tuck-top — that locks closed without tape or glue. The fluted board takes the knocks in transit; the printed liner carries your brand. Because the box is made to the product, there is no void to fill and nothing rattles.
Mailer boxes are the standard for e-commerce, subscription kits, apparel and any product that reaches the customer by courier. Sizing the box to the contents keeps the dimensional weight down and the product from moving; lock tabs and a tear strip add tamper evidence where it is wanted. Printing the interior is what turns a delivery into an unboxing: the first thing the customer sees when the lid lifts is your artwork, not brown board.
- E-flute≈1.5mm
- B-flute≈3mm
- LinerWhite · kraft · printed
Mailer box styles
Four structures, one self-locking idea.
Each construction is sized to the contents and delivered flat to lock up by hand.
Style guides
Read the construction in detail.
Sizing
Cut to the product, so there is nothing to fill
Send the product's dimensions and how many pieces go in each box. We size the mailer to the contents with just enough clearance for an insert or tissue, so the box is smaller, stronger and cheaper to send than a stock size padded out with void fill, and stays inside the dimensional-weight bands the carriers charge on.
Depth matters more than it looks: a roll-end mailer's side walls roll under the lid, so the depth is set to the product and the lock tabs to the depth. If the product varies — a subscription kit that changes monthly, say — tell us the largest configuration and we size to that.
- Measure
- Internal L × W × D of the product
- Tell us
- Quantity, print, finish, insert if needed
- Range
- Set at quote
Materials & finishing
Fluted board, printed liner.
Flute profile is chosen for the product's weight and how far it travels; the liner is chosen for the print. Most mailers run on E-flute with a white or kraft liner, which prints crisply and folds cleanly at the roll-end. B-flute adds cushioning for heavier items at the cost of a slightly softer print surface.
Materials & finishes
- E-flute≈1.5mmFine flute, crisp print surface. The default for retail-weight mailers.
- B-flute≈3mmDeeper flute for heavier products or longer journeys.
- White linerCoated or uncoatedBright surface for full-color print.
- Kraft linerNatural brownMuted print; reads honest and recyclable.
Print & finishing
- Full-color interior print
- Single-color exterior
- Matte or gloss coating
- Spot UV
- Foil stamping
- Tear strips
Customization
Flute, liner and print, chosen for the journey.
Any combination the structure will carry. Options are confirmed against your artwork at quote.
Unboxing
The inside is the part the customer photographs.
Interior print costs a second pass on press and changes how the box is received. Use it for a message, a pattern, a color field or the same artwork as the outside.
- Full-color interior artwork
- Printed tissue and stickers
- Die-cut inserts that present the product
- Thank-you cards and dividers
Compare
Mailer box or folding carton?
A mailer is built to travel; a folding carton is built for the shelf. Many brands use both — the carton inside the mailer.
| Mailer box | Folding carton | |
|---|---|---|
| Board | Corrugated (fluted) | Paperboard (solid) |
| Closure | Self-locking, no tape | Tuck flaps or glued bottom |
| Outside and inside | Outside, sometimes inside | |
| Protection | Takes courier handling on its own | Needs an outer box to travel |
| Typical use | E-commerce, subscriptions, apparel, kits | Retail shelf, cosmetics, food |
Finished work
Mailer boxes we have made.
Roll-end mailers on E-flute, printed outside, inside or both.
Full gallery
Printed inside and out, white liner 
Interior print inside the lid 
Kraft liner, single-color interior 
Lid raised, full-color interior 
Black exterior, striped interior 
Kraft mailer with a partition insert 
Full-color exterior print 
Die-cut board insert
Industries we serve
Who ships in custom mailers.
Different sectors fail in different ways — grease, humidity, compliance, drop height, shelf angle. We specify for yours.
All industries
How it works
From dimensions to a printed mailer.
You do not need a dieline, a spec sheet or print-ready artwork to start. You need to know roughly what you are packing.
Tell us what you're packing
Product dimensions, weight, quantity and what the box has to survive. A photo or sketch is enough to start.
Flute, liner & lock style
We size a roll-end tuck-top to the contents, choose E-flute or B-flute against the product's weight and route, and issue a dieline showing the lock tabs, dust flaps and any tear strip.
Inside & outside print
White or kraft liner, one-color or full-color print, outside only or inside and outside. Coating and foil are chosen for how the box is handled on the way to the customer.
Proof & production
You approve a proof before anything is cut. Mailers are printed, die-cut and scored, then delivered flat to fold and lock on your bench. Quantities and lead time are stated in writing.
Delivery
Finished packaging is delivered free to your address in the United States, flat or assembled as the structure requires. Allow 3–5 working days for ground shipping after production.
Start a quote
Three answers is all it takes to open a job.
Structure, board and finishing come next — with our team, on the full quote form.
No account needed. Artwork and reference images can be attached on the next step.
Mailer box questions
Before you ask.
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat makes a custom mailer different from a plain carton?
A custom mailer is made to your product and printed with your brand, inside and out — it is the packaging, not a container for it. A plain commodity carton is a stock size around whatever fits, padded out with void fill. We make the former.
Can you print inside the mailer box?
Yes. Interior print is a second pass on press and is the most effective single upgrade for an unboxing.
Which flute should I choose?
E-flute for most retail-weight products and the sharpest print; B-flute for heavier items or long journeys. We recommend against your weight and route.
Does a mailer box need tape?
No. Roll-end tuck-top mailers lock closed on their own. Locking tabs or a tear strip can be added for tamper evidence.
What is the minimum order for custom mailer boxes?
The minimum order for custom mailer boxes is 50 boxes. Pricing steps down at higher quantities, and your quote shows the price at each quantity you ask for.
Can you make a completely custom size?
Yes. Every box is cut to your product's dimensions rather than picked from a stock list, and a dieline is produced for your job.
What artwork files do you need?
Print-ready vector artwork — AI, PDF or EPS — with fonts outlined and images at 300 dpi, laid onto the dieline we supply. If you only have a logo, our design team prepares the print-ready files with you.
Can I get a sample before the full run?
Standalone samples are chargeable, because making one box or a handful takes the same setup and production steps as a full run. On a qualifying bulk order, once the order is placed we produce a pre-production sample for your approval at no extra sample charge, and the remaining quantity runs after you approve it.
How long does production take?
Standard production is 10–12 working days from proof approval and payment. Ground shipping adds 3–5 working days, and delivery is free on every order.
Do you work with agencies and resellers?
Yes. Agencies, designers, print brokers and resellers place packaging with us under their own client relationship; see Agency & Trade Partners for how a partner job runs.
Resources
Before you specify a mailer
Mailer boxes vs folding cartons: shelf packaging and courier packaging are different jobs
A mailer is built to travel; a folding carton is built for the shelf. Many brands need both. Here is how they differ and how to combine them.
Read the guideHow to measure your product for custom packaging
Length, width, depth — and the clearance, weight and count that turn those numbers into a box that fits. What to measure and how to send it.
Read the guidePreparing artwork for custom printed boxes
Dielines, bleed, color, resolution and finish layers. What print-ready packaging artwork looks like and how to get there from a logo.
Read the guide
Related packaging
Often specified alongside mailer boxes.
Placing this for a client?
Agencies, designers, print brokers and resellers run mailer boxes through us under their own client relationship: estimating, dielines, sampling, production and delivery behind your studio.
Start here
Send us your dimensions. We’ll send back a box.
Get a Custom Quote
Or talk to a packaging specialist: (209) 444-0744