FREE Shipping All Across the USA No minimums, no hidden freight fees — to all 50 states.
FREE 3D Design Tool Build & preview your box online before you order.
FREE Design Support Our US team perfects your artwork & 3D mockup.
Custom mailer boxes are the e-commerce workhorse: a one-piece die-cut design with front tuck and side wings that fold and lock without tape or glue. Built from sturdy corrugated, they survive the carrier journey while turning delivery into an unboxing moment. Printed inside and out in full-color CMYK, they're ideal for subscription brands, DTC startups, and anyone shipping direct to US customers. We manufacture in Cheshire, Connecticut, ship flat to save you freight, and start runs at 100 units with no setup or die charges and free contiguous-US shipping.
For US e-commerce and subscription brands that want a branded, tape-free unboxing that still ships safely.
Make every delivery memorable with Printed Mailer Boxes! Self-locking designs, tear-resistant materials, and full-color printing. Ideal for subscription services and direct-to-consumer brands.
About Custom Mailer Boxes
The e-commerce unboxing, engineered to survive shipping
A mailer box has two jobs that pull in opposite directions: protect the product through a rough carrier network, and deliver an unboxing moment worth photographing. Custom mailer boxes solve both with a one-piece, die-cut design that folds and locks with no tape or glue, ships flat to save you freight and storage, and prints full-color inside and out. We manufacture in Cheshire, Connecticut on sturdy corrugated, so US brands skip overseas lead times and ship with confidence — and runs start at 100 units with no setup, plate, or die charges, so a first product drop and a national subscription program can both get the same quality.
Mailer & shipping box styles
The right build depends on weight, fragility, and how premium the open should feel:
- Printed mailer boxes — full-color interior and exterior for a branded unboxing.
- Corrugated boxes and shipping boxes — single- or double-wall board for heavier or fragile shipments.
- Die-cut boxes and cardboard boxes — custom shapes and inserts cut to your exact product.
Built for subscription & DTC brands
Repeat-purchase brands live in the mailer — it is the one physical moment they own with every order:
- Subscription boxes for recurring shipments and curated drops.
- Apparel boxes for fashion, accessories, and soft goods.
- Book & media boxes with snug, corner-protecting fits.
- Gift boxes for direct-to-recipient sends.
Premium unboxing alternatives
When the product warrants a more elevated open, we build the mailer up a tier:
- Rigid boxes for a dense, gift-grade feel.
- Magnetic-closure boxes for a satisfying, reusable open.
- Folding cartons for lighter, lower-cost retail-and-ship hybrids.
Designing a mailer that protects and brands
A great mailer is right-sized and right-printed. We engineer the dieline to your exact product so it does not rattle in transit — and so you are not paying dimensional-weight penalties on empty space — add inserts or product trays where fragility demands it, and put your strongest art on the interior walls where the customer sees it first at the open. Our US-based designers build the dieline or polish your artwork, send a free 3D mockup, and a free physical sample on request, so you can drop-test the real box before a full run.
Why US brands choose us for custom mailer boxes
Custom Box Printing manufactures custom mailer boxes from our US production facility, with free standard shipping anywhere in the contiguous United States and a 7–10 business day turnaround. We've printed custom mailer boxes for solo founders launching their first product line, growing direct-to-consumer brands placing 5,000-unit runs, and established retail brands with 50,000+ unit production schedules — and we treat all three the same: no minimums, free design support, no setup or die-plate charges, and a 3D digital mockup before anything goes to press.
Every custom mailer boxes order includes free in-house dieline and artwork support — our US-based designers will polish your existing files, or build a custom dieline from scratch to fit your exact product dimensions. We send you a 3D mockup to confirm look and proportions before production. For color-critical work, request a physical sample free — let’s talk about a customized sample so you can confirm the look before a full run.
Custom Mailer Boxes — specifications & options
| Box Style | Custom Mailer Boxes |
|---|---|
| Dimension ( L + W + H) | All Custom Sizes & Shapes |
| Quantities | No Minimum Order Required |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored, Perforation |
| Additional Options | |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 4 – 8 Business Days, RUSH |
| Shipping | FLAT |
Materials, print, and finish options
Mailers are built on E-flute (1.5 mm) corrugated for a smooth, print-friendly surface and crush resistance, stepping up to B-flute for heavier or fragile contents. The fluted core absorbs transit shocks while the die-cut, self-locking walls assemble in seconds. Add gloss or matte lamination for scuff resistance, soft-touch for a premium hand, or print the interior for a branded reveal — all on kraft or white stock.
Available finishes include:
- Lamination: Gloss, matte, soft-touch, or velvet finish for a premium hand-feel.
- Foil stamping: Gold, silver, copper, or custom foil colors for high-visibility brand marks.
- Embossing & debossing: Tactile raised or recessed surface effects on logo or key artwork.
- Spot UV: Selective gloss coating that creates contrast against matte areas.
- Eco-friendly options: Recycled kraft, FSC-certified stocks, water-based inks, recyclable rigid constructions.
- Compliance: FDA food-safe inks; certified child-resistant constructions for CBD/cannabis where required.
If you're not sure which combination will work best for your custom mailer boxes, mention it in your quote request — our team will recommend the right material, print spec, and finish based on your product, budget, and brand positioning.
How to order your custom mailer boxes
- Request a quote — use the "Get Free Quote" button on this page, or call (855) 792-3890 (toll free). Tell us your box style, dimensions, quantity, material preferences, and any deadline.
- We respond within 1 business day with pricing, lead times, and material recommendations. No pressure, no commitment.
- Free design + 3D mockup — we build your dieline (or polish your existing artwork) and send you a 3D digital mockup to approve.
- Optional physical sample — request a free custom sample to hold the real box in hand — let’s talk it through.
- Production & free US shipping — once you approve, we print and ship in 7–10 business days, free anywhere in the United States.
Custom Mailer Boxes — Frequently Asked Questions
