Mailer boxes sized around the product
We measure what goes in the box, add the right clearance, and cut the board to that. Less void fill to buy, less movement in transit, less dimensional weight on every shipment.
Custom Mailer Boxes · USA
Custom mailer boxes
built around your product.
We manufacture custom printed mailer boxes cut to your product's exact dimensions — so nothing rattles in transit and no delivery looks off-the-shelf. Wholesale mailer boxes from 50 units, shipped free across the USA.
50Low MOQ — minimum order
4–6dStandard turnaround
$0.15Per unit, from
12,400+Orders shipped
2,500+Brands packaged
4.9/5Average rating
98%On-time delivery
Trusted on Trustpilot, Google & Bark
Why The Mailer Packaging
Custom packaging that starts
with what goes inside.
Plenty of custom box suppliers will print whatever file you send them. We begin a step earlier — with the product, how far it travels and what it should feel like to open — and you can reach an actual person while we do it.
Print that holds its colour
Full-process CMYK or a Pantone spot match, outside and in. We tell you up front how a colour will behave on kraft rather than after the run.
Low minimum, real wholesale pricing
Test a mailer box design at 50 units without being treated as a nuisance, then scale to 50,000 on the same line with wholesale pricing that steps down as you go.
Four to six days, honestly quoted
The clock starts when you approve the proof, not when you place the order. If a date is at risk we say so before you commit, and rush slots exist.
Recyclable unless you ask otherwise
Kraft and corrugated go straight in the curbside bin. If you want a laminate finish we will tell you what it costs you in recyclability first.
A designer, not a ticket queue
Someone who sets up packaging artwork every day checks your dieline, your bleed and your fold allowances before anything reaches the press.
Best Sellers
Best-selling mailer box styles
On Sale Custom
Electronics Packaging
Laptop & Tablet Mailer Boxes
On Sale Custom
Electronics Packaging
Power Bank Mailer Boxes
On Sale Custom
Electronics Packaging
Headphone Mailer Boxes
On Sale Custom
Electronics Packaging
Charger & Cable Mailer Boxes
On Sale Custom
Electronics Packaging
Phone Accessory Mailer Boxes
On Sale Custom
E-commerce & Shipping Boxes
Plain Mailer Boxes
On Sale Custom
Tuck & Lock Cartons
Tab Lock Mailer Boxes
On Sale Custom
Tuck & Lock Cartons
Reverse Tuck Boxes
How It Works
Ordering custom boxes in four steps.
01
Send the specs
Dimensions, quantity and whatever artwork exists — even a sketch. You get itemised pricing back, usually the same working day.
02
Check the proof
We return a print-ready dieline and a 3D mockup with your artwork on it. Nothing moves forward until you sign that off.
03
Onto the press
Digital, litho or flexo depending on your run size — we pick whichever gives you the better price at that quantity, not the one that suits us.
04
Flat-packed to your door
Boxes travel flat so you pay freight on cardboard rather than air, and arrive ready to fold at the packing bench.
Materials & Finishes
Every packaging option, priced.
Board, flute, print method and finish are four separate decisions. Each one moves the price, and we will tell you which ones are worth paying for on your product.
Stock & flute
- Kraft corrugatedE-flute · 1.5mm
- White corrugatedB-flute · 3mm
- Rigid / chipboard16–28 pt
- Double-wallEB-flute
Printing
- CMYK 4-colorFull process
- Pantone (PMS)Spot match
- Inside printAvailable
- Flexo / digital / offsetBy volume
Finishes
- Matte / gloss lamSoft-touch
- Spot UVGloss accents
- Foil stampingGold / silver
- Emboss / debossTactile
Add-ons
- Custom insertsFoam / board
- Tear stripsEasy open
- Tissue & stickersUnboxing kit
- Eco inksSoy-based
100%Recyclable & biodegradable stock options
FSC-certified paper sources
Water- & soy-based inks
Plastic-free by default
Sustainability
The greenest mailer box is the one that fits.
Recyclable board matters, and ours is. But the bigger win is usually sizing: an oversized box burns fibre, needs filling with something, and ships air across the country on every single order. Getting the dimensions right removes more waste than any material swap — and it lowers your freight bill while it does it.
- Curbside-recyclable kraft and corrugated stock
- Water- and soy-based inks, plastic-free as standard
- Right-sizing that removes void fill instead of hiding it
What a custom mailer box actually is
A custom mailer box is cut and creased from a single sheet of corrugated board. It arrives flat, folds up without tape, and locks shut with a front tab. That construction is why it became the default for eCommerce: flat storage takes almost no warehouse space, assembly takes a few seconds at the packing bench, and the corrugated flute absorbs the knocks a parcel takes between your unit and someone's doorstep.
The part worth understanding is that the dimensions you order are internal — the usable space once the board is folded. Get those right and the product sits still. Get them wrong by a centimetre and you are either fighting the lid closed or paying to ship empty space.
Where a custom printed mailer box earns its cost
A plain shipping box gets the product there. A branded mailer box does that and puts your name in someone's hands at the one moment they are guaranteed to be paying attention. That is worth something — but it is not the only return, and often not the biggest.
The measurable saving is usually in the sizing. Carriers bill on dimensional weight, so a box two centimetres larger than it needs to be costs you on every order, forever. A snug box also needs less void fill to buy and store, and moves less in transit, which means fewer damages and fewer replacement shipments. eCommerce brands that switch from stock cartons to right-sized custom mailer boxes frequently find the packaging pays for itself on freight alone.
Choosing a mailer box style without overspending
Work from the product outwards. Light, non-fragile goods — apparel, accessories, printed matter — are well served by E-flute corrugated mailer boxes, which are thin, fold crisply and print well. Heavier or breakable items justify B-flute or double-wall board and a fitted insert that stops movement entirely; an insert usually costs less than the volume of paper filler it replaces.
Finishes are where budgets quietly disappear. Soft-touch lamination and foil stamping are genuinely memorable, and genuinely expensive, so they make sense when the box is part of what the customer is paying for — a PR send, a gift item, a premium launch. On a high-volume, low-margin product, a strong one-colour design on kraft often reads more confident than a busy four-colour print, and costs a fraction.
If you would rather not guess, send us the product, the quantity and the ceiling you want to stay under. We come back with a mailer box spec that fits it, plus a free dieline and a 3D mockup so you can judge it before committing.
Industries we supply custom packaging to
We manufacture wholesale custom packaging for beauty and cosmetics, apparel, supplements, candles and home fragrance, small electronics, coffee and specialty food, pet products and eCommerce subscription brands across the United States. The categories differ, but the questions rarely do: what does it weigh, how far does it travel, how fragile is it, and what should it feel like to open.
Beauty & cosmeticsApparel & fashionSubscription boxesSupplementsCandles & homeElectronicsCoffee & foodPet products
Fifty. That is a genuine production run for us, not a favour — it is the right quantity to prove a mailer box design works before you commit to thousands. Wholesale pricing steps down at 250, 500, 1,000 and beyond.
Yes — every mailer box is cut to your own length × width × height. Send the measurements of the product rather than a box you already have, and we add the right clearance and build the dieline around it.
Four to six working days from the moment you approve the proof, plus transit. The clock does not start at the order — it starts at approval, so a slow sign-off moves the date.
Yes, across the continental US, and it is included in the quoted price rather than added at checkout. Anything that arrives damaged gets replaced.
Yes, and it is included. A packaging designer checks your bleed, fold allowances and colour build before the job reaches the press — that is where most first-time print problems get caught.
Kraft and corrugated board goes in the curbside bin, and we print with water- and soy-based inks on FSC-sourced paper. Worth knowing: plastic lamination makes a box harder to recycle, so ask for a water-based varnish if that matters to you.
From the Journal
Guides worth reading
Blogs
August 27, 2026
What packaging actually costs: a breakdown of your quote
Why 250 boxes and 1,000 boxes are priced so differently, what setup costs cover, and the four levers…
Blogs
August 27, 2026
Corrugated, kraft or rigid: choosing the right board for your box
Single wall, double wall, kraft, white-top, rigid chipboard — a plain-English guide to what each material actually does…
Blogs
August 27, 2026
How to measure a mailer box so your product does not rattle
Most first-time packaging orders fail on one detail: the dimensions. Here is how box sizing actually works, why…
Ready when you are
Start with the
measurements.
Give us the product dimensions and a quantity. You get itemised wholesale pricing on your custom mailer boxes, a free dieline and a 3D mockup — no charge, no obligation.