Custom Mailer Boxes & Wholesale Packaging
Corrugated mailer boxes, rigid boxes, shippers and custom inserts — all cut to your own dimensions and printed to your brand. Browse the range and request wholesale pricing on any style.
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
On Sale Custom
The short version
- Pick the board by weight and fragility, not by price — over-specifying is the commonest way to overpay.
- Unit price drops in steps, so 500 often costs far less per box than 250.
- Every listed size can be made to your own dimensions instead.
- Free dieline, 3D mockup and itemised pricing with every quote.
Which box style do you need?
Most of this catalogue is variations on one structure. A custom mailer box is cut from a single sheet of corrugated board, arrives flat, folds without tape and locks with a front tab. Work from the product outwards — how heavy it is, and how much it would mind being dropped.
| Style | Board | Best for |
|---|---|---|
| Mailer box — E-flute | 1.5 mm | Apparel, accessories, cosmetics, printed matter. Thin, folds crisply, best print surface. |
| Mailer box — B-flute | 3 mm | Heavier or breakable items, or long courier journeys. Noticeably tougher, slightly coarser print. |
| Double-wall shipper | 4.5 mm | Heavy, fragile or high-value goods. Two bonded flutes for serious crush resistance. |
| Rigid box | 16–28 pt | Gift, PR and premium launches. Does not fold flat and costs several times more — worth it when the box is part of what you are selling. |
| Custom insert | Board / foam | Stops movement entirely. Usually cheaper than the volume of loose filler it replaces. |
How wholesale pricing works
Every packaging price is a fixed setup cost plus a per-unit running cost. Setup — cutting the die, making plates, calibrating the press — costs the same whether you order 100 boxes or 10,000. So it is the division by quantity that moves your unit price, not the board.
| Quantity | Setup share of unit price | Typically ordered by |
|---|---|---|
| 50 — our minimum | Highest — setup dominates | Testing a design before committing to it |
| 250 | Noticeably lower | A first real run for a new product |
| 500 | Lower again — the common sweet spot | Where most growing brands land |
| 1,000 | Nearly marginal | Steady monthly shipping volume |
| 2,500+ | Flat — you are paying for board | Established volume; savings now come from materials |
The step from 250 to 500 usually saves more per box than the step from 1,000 to 2,500.
Ordering a size that is not listed
Every product here can be made to your own internal dimensions — the listed sizes are starting points, not a fixed range. Send the length, width and height of the product rather than a box you already use, and we add the clearance and board thickness ourselves.
You get a print-ready dieline, a 3D mockup and itemised pricing back at no charge. If trimming a few millimetres would fit more boxes per sheet and drop your cost, we will tell you before anything is printed.
Any size, made
to order.
Send the product dimensions and a quantity — we engineer the dieline around it and quote wholesale pricing the same working day.