FREE Shipping All Across the USA Low MOQs, 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.
Mailer boxes are the standard for shipping products direct to customers: a one-piece corrugated design that folds into a rigid box with self-locking wings — no tape, no void of structural strength. The fluted wall protects contents in transit while the flat profile keeps freight and storage costs down. They suit apparel, books, cosmetics, food, and electronics alike. Ships across the USA, our mailers start at 100 units with no setup or die charges, ship flat, and qualify for free shipping anywhere in the contiguous US.
For US shippers that need a strong, stackable, tape-free box that arrives flat and assembles fast.
What are Mailer Boxes?
Mailer Boxes are custom-printed cartons produced in the mailer structural style — cut, scored, and printed to your exact dimensions and brand artwork so the box fits the product, ships flat to save freight, and assembles cleanly at your warehouse.
What are mailer boxes used for?
US brands use custom mailer boxes across a handful of common channels:
- E-commerce and subscription-box fulfillment
- Retail shelf and endcap placement
- Gifting, promotional, and holiday programs
- High-value product protection during shipping
- Multi-SKU brand systems where structure has to be consistent
How to choose the right size for your mailer
Measure the product at its widest length, width, and height including any inner protection (foam, paper crinkle, insert), then add 1/8–1/4 in of tolerance on each dimension for a snug fit. Under-sizing crushes product in transit; over-sizing wastes material and freight. If you're building a subscription assortment, spec one flat-pack mailer size that holds the largest possible SKU combination — cheaper than running several sizes.
Not sure which size to spec? Send us your product dimensions in your quote request and our design team will recommend a dieline sized to your product — free, before you commit.
How can you customize your mailer boxes?
Every element of the box is customizable — you choose:
- Size & shape: Any dimension, any dieline — cut and scored to your exact product footprint.
- Material: SBS, kraft, recycled paperboard, corrugated (E/B/F flute), or rigid chipboard.
- Printing: Full-color CMYK offset with Pantone (PMS) spot-color matching on brand-critical colors.
- Coatings & lamination: Gloss, matte, soft-touch, velvet, or aqueous coating on the outer surface.
- Foil, emboss & spot UV: Metallic foil stamping (gold, silver, copper), embossing, debossing, and selective spot-UV highlighting.
- Windows & die-cuts: Cut-out windows with or without film inserts, plus custom die-cut shapes and handles.
- Inserts & dividers: Printed paperboard inserts, foam, or molded pulp to hold and protect the product inside the box.
Which printing options are available for mailer boxes?
- Full-color CMYK offset — photographic-quality print for complex artwork, gradients, and product imagery
- Pantone (PMS) spot-color matching — brand-critical colors matched exactly and held consistent across every reprint
- One- and two-color print — lower per-unit cost for high-volume runs or minimalist brands
- Foil stamping — metallic (gold, silver, copper, holographic) or pigment foils applied under heat and pressure
- Embossing and debossing — tactile raised or recessed relief on logo or brand marks
- Spot UV — selective high-gloss coating that highlights specific elements against a matte background
How much do custom mailer boxes cost?
Custom mailer boxes are priced per project, not off a rate card — the number depends on the combination of factors below. Send your specs (or a rough brief) and we'll come back with a full quote inside 1 US business day.
- Order quantity: Per-unit price drops significantly as quantity increases — 100, 250, 500, 1,000, 5,000+ tiers all have different unit economics.
- Box size: Larger dimensions use more paperboard per unit and slightly more press time.
- Material and thickness: SBS and rigid stocks cost more than kraft or recycled paperboard; higher point weights (14, 18, 24 pt) cost more than lighter stocks.
- Print complexity: Full-color CMYK with Pantone matching runs higher than one- or two-color print; full-bleed print higher than white-margin.
- Finishes and add-ons: Foil stamping, embossing, spot UV, windows, and inserts each add a fixed setup plus a per-unit cost.
- Turnaround: Standard 7–10 business day production is included; rush production (3–5 business days) is available for an additional fee.
There are no setup, die-plate, or artwork charges on any run — the price you're quoted is the price you pay, with free US shipping included on every order.
Custom mailer boxes vs stock mailer boxes
Stock boxes come in fixed sizes that rarely match your product, so you either ship air (wasted freight, more damage, worse unboxing) or crush your product to make it fit. Custom mailer boxes are cut to your exact dimensions and printed with your brand, so the box does the job of packaging AND marketing on the same run.
Why US brands choose us for mailer boxes
Custom Box Printing manufactures 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 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: low MOQs (100-unit runs), free design support, no setup or die-plate charges, and a 3D digital mockup before anything goes to press.
Every 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.
Materials, print, and finish options
Standard build is E-flute corrugated (about 1.5 mm) — strong enough for most parcels yet thin enough to fold cleanly and print sharply. For heavier or breakable items, B-flute adds crush strength. Kraft liner gives a recyclable, no-frills look; white liner is ready for full-color print. The double-wall side panels created by the folding design add stacking strength in transit and on the shelf.
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 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 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 custom sample (refunded on your first order) 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.
Mailer Boxes — Frequently Asked Questions
