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
CUSTOM PRINTED MAILER BOXES AND CUSTOM PACKAGING
Being the jack of all trades proves to be beneficial sometimes. As much as advancements are being introduced in the world, some things will always remain the OG. One of them is the ways of marketing yourself as a brand. Packaging boxes have always been important because there is nothing that can be shipped just like that. It is highly important to package the product in a protective box so that it reaches the destination safely. Well, Custom Box Printing has faith in bringing modern twists to the olden. We are talking about mailer boxes; old but gold. We offer these customized mailer boxes in our style and that is why you need them for your products’ packaging.
This is the type of box that is made out of cardboard paper and the sole purpose of its creation was to fulfill storage needs and to make shipments easier. This box is special because of the kind of structure it has. Our mailer boxes have flaps that interlock into each other along with extensions that form the double exterior of the box sides, hence, ensuring the full protection of the product inside. Getting these boxes from us means that you will not waste any minute by working on the box.
Our boxes are always partially assembled by pre-scoring and pre-gluing. This is to make things easier for you, just pop back up the box and it will stand on its base. Place in your product and close the lid by inserting the front two flaps in the inserts. The structure of our mailer box is highly reliable and since this traditionally iconic box has been known to have sturdy features, it will maintain its composure throughout the transit. This box is known for being better than all other types of packaging boxes for so many reasons and we agree to every point of it!
PACKAGING OF MAILER BOXES
Our customized mailer boxes have versatile options in the domain of design. You can create any kind of crazy design that you want to. These can be used as gift boxes, subscription boxes, storage boxes, or for anything instead of being confined for shipment purposes. Since we use sturdy material for manufacturing, these boxes can incorporate any kind of product. No matter how fragile, the product will remain safe.
Custom Box Printing offers premium quality and flexible customization options; get the design of your choice to ensure your boxes communicate what your brand stands for. Select the innovative template of your choice with the color palette of the aesthetic vibe. This will take the looks of your boxes to another level and we compliment all of this hard work with precise printing that accentuates the design work. In the end, select a mesmerizing finishing style that suits your box best. Voila, you have a captivating product which is all ready to hit the market.
GET IN TOUCH
Whenever you are ready, Custom Box Printing will get on with the grind!
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
