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Mailer Box
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Mailer Box

A mailer box is a single-piece corrugated carton with interlocking tuck-top flaps that lock shut without tape. Most use E-flute corrugated board (1/16 inch thick), which keeps the walls rigid enough to survive courier sorting machines while staying light enough to avoid dimensional weight surcharges. The flat-packed format ships to your warehouse in bundles of 25-50 and pops open by hand in about three seconds. Both the exterior and interior print in full color, so brands use the outside for logo work and the inside for care cards, social handles, or loyalty program codes. Standard material is 350gsm or 400gsm kraft-backed white liner. Cubit produces custom mailer boxes starting at 100 units with 8-12 business day turnaround.

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4 Materials Available
7 Finishes Available

Best For:

E-Commerce & D2C ShippingSubscription BoxesApparel PackagingBook & Media MailersGift Box KitsSample Kits
Free Shipping
8-12 Day Production
MOQ 100 Units

Technical Specifications

assembly
Fold and lock — no tape needed
max size
20 x 16 x 8 inches
min size
4 x 4 x 1 inches
closure type
Self-locking interlocking flaps
ideal weight range
Up to 25 lbs
material compatibility
Corrugated Cardboard, Kraft Paper, White Cardboard

Available Materials

Choose the right substrate for your Mailer Box packaging based on product weight, sustainability goals, and print requirements.

White Cardboard

Recyclable

Kraft Paper

Eco Recyclable

Eco Kraft

Eco Recyclable

Corrugated Cardboard

Recyclable

Available Finishes

Enhance your Mailer Box with premium finishes that add tactile appeal and visual impact.

Gloss Lamination

Gloss lamination applies a clear, reflective polypropylene film over the entire printed surface. The film intensifies CMYK color values, making photographs and gradients look sharper and more saturated. Retail toy packaging, snack food boxes, and consumer electronics cartons use gloss lam because the shiny surface catches store lighting and draws attention at a distance. The trade-off is that gloss shows fingerprints and scratches more than matte. Film thickness runs 12-25 microns. The protective layer resists moisture, scuffing, and ink rubbing during transit. Gloss lamination runs through thermal or wet laminating equipment after printing and before die-cutting.

+10% price

Matte Lamination

Matte lamination bonds a thin non-reflective polypropylene film to the printed surface of the carton. The film eliminates glare, slightly mutes color saturation, and gives the box a smooth, flat appearance that reads as understated and premium. Matte lam hides minor printing imperfections and fingerprints better than gloss, which is why cosmetics and luxury food brands default to it. The lamination layer also protects against scuffing, moisture, and ink transfer during shipping and shelf handling. Film thickness runs 12-25 microns. Matte lamination pairs well with spot UV, where a glossy accent on a matte background creates high-contrast visual interest on logos and typography.

+10% price

Spot UV

Spot UV applies a clear ultraviolet-cured coating to specific areas of the box rather than the entire surface. The result is a glossy, raised accent on logos, typography, or decorative patterns that contrasts against the surrounding matte or uncoated surface. The UV coating cures instantly under ultraviolet light during production, which creates a hard, durable finish that resists scratching. Raised spot UV adds a thicker coating layer (10-20 microns above the surface) that you can feel with your fingertip. This finish requires a separate printing plate aligned precisely to the artwork, so setup costs are higher than full-surface coatings.

+12% price

Embossing

Embossing uses a matched set of metal dies to push the carton material upward, creating a raised three-dimensional pattern or logo on the surface. The male die presses from behind while the female die shapes the front face. The depth of the emboss depends on material thickness and fiber direction, typically ranging from 0.5mm to 2mm of lift. Deeper embossing works better on thicker board (400gsm+) because the fibers have more room to stretch without cracking. Embossing works without ink or foil for a subtle tone-on-tone texture, or combined with foil stamping for a raised metallic effect. Heat is applied during the process (120-160°C) to help the paperboard fibers hold their new shape permanently.

+15% price

Debossing

Debossing is the reverse of embossing: it presses a design into the carton surface to create a recessed, sunken impression. The male die pushes down from the front while the female die supports from behind. The result is a clean indentation that catches shadows and creates visual depth without adding any material to the surface. Debossing works well for brand logos, decorative borders, and subtle patterns where the tactile quality matters more than visibility from a distance. Like embossing, depth ranges from 0.5mm to 2mm depending on board thickness. Debossing pairs well with matte and soft-touch laminations where the recessed areas create a contrast texture against the smooth surrounding surface.

+15% price

Die Cutting

Die cutting uses a custom-shaped steel blade mounted on a wooden board to cut paperboard into specific shapes during production. Every box shape starts as a flat sheet that passes through a die-cutting press where the steel rule die stamps out the carton blank, score lines, and perforation cuts in a single press cycle. The die is custom-made for each box design, which involves a one-time tooling cost. Die-cut accuracy runs within 0.5mm tolerance on modern flatbed and rotary die cutters. Beyond standard box shapes, die cutting creates custom windows, thumb-cut openings, hang-tab holes, and decorative shapes. Complex dies with many cut lines cost more due to the additional steel rule bending.

+10% price

Soft Touch Lamination

Soft touch lamination applies a specialty matte film that creates a velvety, suede-like texture when you run your fingers over the surface. The tactile effect makes people pick up the box and hold it longer, which is why premium cosmetics, luxury spirits, and high-end electronics brands pay the 30-50% cost premium over standard matte lam. The finish resists fingerprints better than either gloss or standard matte. Soft touch film typically runs 18-30 microns and bonds through thermal lamination. The velvety surface pairs particularly well with foil stamping and raised spot UV, where the metallic or glossy accents pop against the matte tactile background.

+15% price

Expert Packaging Guide

Mailer Box packaging from Cubit is fully customizable with 4 material options including White Cardboard, Kraft Paper, Eco Kraft and 1 more and 7 finish options. Every order includes free design assistance from our packaging engineers, who will help you select the optimal material weight, finish combination, and structural configuration for your specific product.

Our clients use Mailer Box packaging across industries including E-Commerce & D2C Shipping, Subscription Boxes, Apparel Packaging, Book & Media Mailers, and 2 more applications. With a minimum order quantity of just 100 units and standard production turnaround of 8-12 business days, Cubit makes custom Mailer Box packaging accessible to businesses of every size—from startup brands to enterprise operations processing thousands of units daily.

All Mailer Box packaging is produced using food-safe inks and coatings, and every order undergoes a three-stage quality inspection before shipping. Free ground shipping is included on all orders within the continental United States.

Frequently Asked Questions

What is a Mailer Box box?

A mailer box is a single-piece corrugated carton with interlocking tuck-top flaps that lock shut without tape. Most use E-flute corrugated board (1/16 inch thick), which keeps the walls rigid enough to survive courier sorting machines while staying light enough to avoid dimensional weight surcharges. The flat-packed format ships to your warehouse in bundles of 25-50 and pops open by hand in about three seconds. Both the exterior and interior print in full color, so brands use the outside for logo work and the inside for care cards, social handles, or loyalty program codes. Standard material is 350gsm or 400gsm kraft-backed white liner. Cubit produces custom mailer boxes starting at 100 units with 8-12 business day turnaround.

What materials are available for Mailer Box packaging?

Mailer Box packaging is available in White Cardboard, Kraft Paper, Eco Kraft, Corrugated Cardboard. Each material offers different properties for strength, sustainability, and print quality.

What is the minimum order quantity for custom Mailer Box boxes?

Custom Mailer Box boxes start at 100 units with full-color printing, custom sizing, and your choice of materials and finishes. Volume discounts apply for orders of 500+ units.

How long does it take to produce custom Mailer Box packaging?

Standard production for custom Mailer Box boxes is 8-12 business days after artwork approval. Rush production is available in 5-7 business days for an additional fee. Free shipping on all orders within the continental US.

What products are best suited for Mailer Box packaging?

Mailer Box packaging is ideal for E-Commerce & D2C Shipping, Subscription Boxes, Apparel Packaging, Book & Media Mailers, Gift Box Kits, Sample Kits. The structural design and material options make it versatile enough for products ranging from lightweight cosmetics to heavier food items.

Other Box Styles

Seal EndMylar BagsFive Panel HangerSleeve BoxesHanger BoxesDispenser Boxes

Ready to Order Mailer Box?

Get a custom quote with your specifications. Our packaging engineers respond within 15 minutes during working hours with material recommendations, pricing, and structural guidance.