Custom mailer boxes are strong and stylish packaging boxes designed for shipping, storing, and presenting products. E-commerce brands, retail businesses, and online stores mainly use these boxes. You can customise these boxes with your brand logo, colors, size, design, and printing options to create a better unboxing experience.
Our shipping mailer boxes help protect products during delivery and make your brand look professional. These boxes are perfect for clothing, cosmetics, subscription boxes, electronics, books, gifts, and other retail products. We create packaging solutions that match your product needs and brand identity.
Order your customized boxes from The Box Packaging today and get a free quote!
We craft sturdy mailer packaging boxes using 100% recyclable, FSC-certified materials that protect your products while keeping your brand green. Choose the ideal material base for your custom packaging:
Kraft Mailer Boxes for a Natural Look
Kraft mailer boxes are a great choice for brands that want an eco-friendly and simple appearance. They are popular for handmade products, organic items, and sustainable packaging.
Standard White Corrugated
We manufacture standard white corrugated boards with b leached, high-durability paper liners. Available across E-Flute and B-Flute profiles, this clean canvas makes bold custom printing and high-contrast logos pop during routine shipping.
Cardboard Mailers for Lightweight Products
Cardboard mailer boxes are suitable for lightweight products that do not need heavy protection. They are commonly used for clothing, documents, cosmetics, and small retail items.
Premium White Corrugated
We craft premium white corrugated stock using an ultra-smooth, clay-coated paper finish. Built around precision-cut E-Flute geometry, this option delivers true-to-life HD colours and a seamless unboxing experience for your shoppers.
Rigid Material
For sturdy boxes, we use rigid boards that are highly dense and compact, with a thickness of 1.5mm to 3mm. This strong construction provides excellent crush resistance and protects delicate retail items.
Every product needs the right packaging style for better protection and presentation. We offer different custom mailer box designs to match your product size, shipping needs, and brand goals. Choose a box style that gives your customers a safe and memorable unboxing experience.
Roll-End Tuck-Top Mailer Boxes
Roll-end tuck-top mailer boxes offer strong protection with a clean, professional look. They are ideal for clothing, cosmetics, accessories, and retail products.
Self-Locking Mailer Boxes
Self-locking mailer boxes feature a secure design that closes easily without extra tape. They are perfect for fast packing and safe product delivery.
Subscription Mailer Boxes
Subscription mailer boxes are designed for monthly product deliveries and brand experiences. They help businesses create attractive packaging that keeps customers excited.
E-commerce Shipping Mailers
E-commerce shipping mailers are made for online stores that need durable packaging for delivery. They protect products during shipping and support a smooth customer experience.
Roll End Tuck Front Mailer Boxes
Roll end tuck front mailer boxes use a front locking tab to keep the box securely closed. They are a great choice for heavier retail products that need extra protection during shipping.
Roll End with Locking Cover Mailer Boxes
These mailer boxes include a built-in locking cover that creates a premium look and strong closure. They work well for luxury products, gifts, and high-value items.
Front Lock Mailer Boxes
Front lock mailer boxes use secure locking wings to hold the package in place. They reduce the need for extra tape and provide a clean, professional look.
Full Overlap Mailer Boxes
Full overlap mailer boxes have extra flap coverage that adds strength and durability. They suit heavy products that need better stacking and shipping protection.
Auto Bottom Mailer Boxes
Auto bottom mailer boxes come with a pre-glued base that opens quickly and saves packing time. They are ideal for businesses handling large numbers of orders.
We offer custom mailer boxes in different sizes to match your product requirements. A properly sized box helps reduce space, improves product protection, and can lower unnecessary shipping costs. Choose from standard sizes or create custom dimensions based on your product needs.
Small Mailer Boxes:
Perfect for lightweight products such as jewelry, cosmetics, accessories, and small retail items.
Medium Mailer Boxes: Ideal for clothing, subscription products, books, and everyday e-commerce items.
Large Mailer Boxes:
Designed for bigger products that need extra space and stronger protection.
Custom Dimensions:
Get cardboard mailer boxes made according to your exact product size, shape, and shipping requirements.
Need help choosing the right size? Our packaging experts can recommend the best box dimensions based on your product.
Packaging inserts help keep products secure inside custom mailer boxes during shipping. They prevent movement, reduce damage risks, and create a professional unboxing experience for customers.
EVA Foam Inserts
EVA foam inserts provide soft cushioning and shock protection for fragile and premium products. They are commonly used for electronics, cosmetics, jeweler, and luxury items.
Cardboard & Corrugated Inserts
Cardboard and corrugated inserts offer an affordable, recyclable way to organize products inside the box. They are ideal for subscription boxes, retail products, and e-commerce shipments.
Molded Pulp Inserts
Molded pulp inserts are an eco-friendly packaging solution made from paper fibers. They protect fragile products and support brands looking for sustainable packaging options.
Tray Inserts
Tray inserts create separate compartments to hold products neatly in place. They are often used for cosmetics, bottles, gift sets, and retail packaging.
Professional printing helps turn ordinary packaging into a branded experience. The right printing method improves product presentation, strengthens brand recognition, and creates a memorable unboxing moment.
Digital Printing
Digital printing is the best choice for small orders, product samples, and seasonal packaging designs. It allows flexible designs without traditional printing plate setup.
Offset Printing
Offset printing delivers premium-quality graphics with sharp details and consistent colors. It is commonly used for personalized mailer boxes that require detailed artwork and luxury finishes.
Flexographic Printing
Flexographic printing uses flexible plates and fast-drying inks to print logos, text, and simple designs on corrugated mailer boxes. It is a cost-effective option for large-volume packaging orders.
Inside & Outside Box Printing
Interior and exterior printing adds extra branding space to your printed mailer boxes. Add patterns, messages, product stories, or promotional codes to create a better unboxing experience.
CMYK & Pantone Color Matching
Precision ink mixing aligns every run with your exact visual identity. CMYK combines four core inks for rich full-colour graphics, while Pantone (PMS) formulas match specific brand shades identically across every single box.
Our exclusive surface coatings guarantee that your personalized mailing boxes will be completely protected from scratches and also create an incredible unboxing experience for you:
Spot UV Coating: Applies a targeted, high-gloss layer over specific logos or artwork to create a striking contrast against a smooth matte background.
Matte Lamination: Delivers a soft, glare-free finish that gives your packaging an elegant, modern feel while offering scratch resistance during shipping.
Gloss Lamination: Adds a reflective, vibrant shine that enhances color saturation and makes graphics, text, and photos pop instantly.
Foil Stamping: Presses brilliant metallic foils, like gold, silver, or rose gold, onto paperboard for a high-end, luxury reflective detail.
Embossing & Debossing: Creates raised or recessed 3D textures on your designs, adding an expressive tactile dimension that customers can feel.
We combine both functional and decorative additions to create added security, provide better convenience, and increase the attractiveness of our customized printed boxes:
Window Cutouts: Die-cut cutouts covered with transparent, recyclable PET film, giving customers a chance to see your product through the box without opening it.
Tear Strip Cutouts: Perforated cutouts designed to let customers open the box easily without scissors.
Double Adhesive Strips: Double peel-and-seal tape strips that make assembly quick and easy and allow easy return of the same product in the same box.
Ribbon & Cord Handles: Soft cotton, satin, or hemp handles attached directly to the packaging, turning standard mailers into portable retail carry-outs.
Custom Closing Stickers & Seals: Branded tape, foil seals, or paper stickers that add an extra layer of security while reinforcing your brand identity.
The Box Packaging has served as one of the most trusted packaging producers for US brands since 2021. We keep production effortless with low 100-box minimums, fast 8–10-day turnarounds, and free shipping across the US with zero hidden fees. Our starting price is 0.50$ /Unit.
Partner with us to build custom mailer boxes in USA from scratch or bring your artwork to life with free 3D digital mockups. Contact us today at +1 510-359-5909 or email inquiry@theboxpackaging.com to get your free custom quote!
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