Custom Mailer Boxes with Logo: The Complete Design & Ordering Guide
Why Custom Mailer Boxes with Your Logo Matter
Your mailer box is your customer's first physical touchpoint with your brand. Research from Dotcom Distribution shows that 72% of consumers say packaging design influences their purchasing decisions, and 40% of online shoppers share photos of branded packaging on social media — giving you free marketing with every shipment.
Custom mailer boxes with your logo transform a generic shipping experience into a branded unboxing moment. For e-commerce brands, DTC startups, and subscription services, logo-printed mailer boxes are the single highest-ROI packaging investment you can make.
Types of Logo Printing for Mailer Boxes
Flexographic Printing (Best for 2,500+ Units)
Flexographic printing uses rubber plates to apply ink directly to corrugated board. Best for 1-3 color logos with solid fills. Cost: $0.60–$1.50/box at 5,000 units. Setup includes plate fees of $150–$300 per color.
Digital Printing (Best for 500–2,500 Units)
Full-color CMYK printing with no plates required. Perfect for photographic logos, gradients, and multi-color designs. Cost: $2.50–$5.00/box at 500 units. No setup fees — making it ideal for small business mailer boxes.
Offset Lithography (Best for 10,000+ Units)
The highest print quality available — litho-laminated corrugated produces photo-quality results. A printed sheet is laminated onto the corrugated board. Cost: $1.00–$3.00/box at 10,000 units. Premium option for luxury brands.
Hot Foil Stamping (Premium Add-On)
Metallic foil pressed onto the box surface for a premium look. Available in gold, silver, rose gold, copper, and holographic. Adds $0.15–$0.50/box. Popular for luxury brands and PR kits.
Mailer Box Materials for Logo Printing
| Material | Print Quality | Cost | Best For |
|---|---|---|---|
| White E-Flute | ⭐⭐⭐⭐⭐ Excellent | $$ | Full-color logos, luxury DTC |
| Kraft E-Flute | ⭐⭐⭐⭐ Good | $ | 1-2 color logos, eco brands |
| White B-Flute | ⭐⭐⭐⭐⭐ Excellent | $$$ | Heavy items, electronics |
| Kraft B-Flute | ⭐⭐⭐ Decent | $$ | Industrial, cost-focused |
Interior Printing: The Unboxing Wow Factor
Interior printing is what separates a good mailer box from a memorable one. Print your brand message, social handles, return instructions, or a vibrant pattern inside the box lid. Interior-printed mailer boxes generate 3x more social shares than plain boxes (PackHelp, 2025).
Cost for interior printing: adds $0.20–$0.80/box depending on coverage area and number of colors.
Custom Mailer Boxes with Logo: Pricing Guide
| Quantity | 1-Color Logo (Flexo) | Full-Color (Digital) | Premium (Litho) |
|---|---|---|---|
| 500 units | N/A (min 2,500) | $2.50–$5.00 | N/A |
| 1,000 units | N/A | $2.00–$4.00 | N/A |
| 2,500 units | $1.00–$2.00 | $1.50–$3.00 | N/A |
| 5,000 units | $0.60–$1.50 | $1.20–$2.50 | $1.50–$3.00 |
| 10,000+ units | $0.45–$1.00 | $0.80–$2.00 | $1.00–$2.50 |
How to Design Your Logo for Mailer Boxes
File Format Requirements
Submit your logo as a vector file (AI, EPS, or PDF) at 300+ DPI for best results. PNG files work for digital printing but may lose quality at large sizes. Avoid JPG files — they compress poorly for packaging print.
Color Considerations
For flexographic printing, convert your logo to Pantone PMS colors for exact color matching. For digital printing, CMYK process colors work perfectly. Remember: colors appear differently on kraft vs. white boards — always request a physical proof.
Minimum Order Quantities
Cubit offers custom mailer boxes with no minimum for digital printing — you can order as few as 50 boxes with your full-color logo. For flexographic printing, the practical minimum is 2,500 units due to plate setup costs.
Small business tip: start with 500 digital-printed boxes to test your design and customer response, then scale to flexo at 2,500+ units for the best per-unit cost.
How to Order Custom Mailer Boxes with Your Logo
- Choose your box size — measure your product and add 0.5–1 inch of padding on each side
- Select your material — white for full-color, kraft for eco-friendly
- Upload your logo — vector format preferred (AI, EPS, PDF)
- Pick your print method — digital for 500+, flexo for 2,500+
- Add finishing touches — foil stamping, spot UV, interior printing
- Request a proof — always approve a physical sample before production
Get a free quote for custom mailer boxes with your logo →
Frequently Asked Questions
How long does it take to get custom mailer boxes with my logo?
Standard production is 10–15 business days from proof approval. Rush orders available in 5–7 business days. Digital printing is typically 2–3 days faster than flexographic.
Can I order a sample before committing to a full run?
Yes. Cubit offers pre-production samples for $25–$50 that ship in 3–5 business days. The sample cost is credited toward your final order.
What if my logo has gradients or photographs?
Use digital printing — it handles unlimited colors, gradients, and photographic images with no limitations. Flexographic printing works best with solid colors and simple logos.
Related Guides
- Custom Labels for Small Business: The 5-Minute Ordering Guide
- Poly Mailers with Logo: Brand Your Shipments for Less
- Custom Cosmetic Packaging Boxes: The Beauty Brand Guide
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Order custom mailer boxes. Custom Mailer Boxes → — branded E-flute corrugated with interior printing. From $0.50/unit, 500 MOQ. Browse all mailer boxes →
