How to choose custom mailer boxes
A mailer box has to do three jobs: survive the parcel network, keep your shipping cost down, and make the delivery feel like your brand. Most of the decision comes down to three choices: the board, the size, and where you print.
Sizes and styles
The classic roll-end tuck-front mailer folds from one flat sheet, locks without tape and opens like a lid, which is why it is the default for subscription and direct-to-consumer orders. Choose a roll-end mailer for most products, a shoulder mailer when you want a rigid-box feel, or mailer boxes with inserts when the product must not move. Size the box around the product plus any insert, not the other way round: every extra inch adds void fill and can push the parcel into a more expensive dimensional-weight tier.
Materials
Corrugated board is the standard. E-flute is thin and prints sharply, and suits most products under a few pounds. B-flute or double-wall is stronger and better for heavy, fragile or stacked shipments. White-lined board gives the brightest print; kraft gives a natural look and hides scuffs in transit.
Finishes that work best
Inside printing is the most effective upgrade: the customer sees it the moment the lid opens. Matte lamination resists scuffing on the outside, aqueous coating keeps the box easy to recycle, and foil stamping on the lid adds a premium detail for PR and gift boxes.
Pricing drivers
Quantity has the biggest effect on unit price, followed by box size, board grade, how many sides are printed and the finishes you add. Printing inside and out costs more than outside only, so ask for both prices if you are unsure. Ask us to quote two or three quantities to see where the price breaks fall.
Before you order
- Pack a real order. Put the product, insert, tissue and any printed card in a test box. Thickness adds up quickly and a box that fits the product alone may not close.
- Check your carrier's size tiers. A box a quarter of an inch smaller can move into a cheaper dimensional-weight band, which matters more than the price of the box over a year.
- Decide who opens it. A customer at home sees the inside print; a warehouse packer cares about how fast the box folds. If both matter, choose a roll-end tuck-front style with a tear strip or tuck tabs that are easy to close.
- Keep artwork off the folds. Small text and thin lines that cross a score can crack. Our proof shows every fold line so you can move them before printing.
Minimum order and lead time
Most styles start at 100 units; some specialty styles have a higher minimum, shown on each product page. Production takes 7–10 business days after you approve the digital proof, and US shipping adds 5–7 business days. Rush production in 5–7 business days is available for an additional fee. Every quote includes a free 3D design and dieline, so you can check the structure before you order.
Read more in our mailer box guide and mailer boxes vs shipping boxes.
