The Box That Sells Before It Opens
The #1 e-commerce shipping box. Custom-printed corrugated mailers with roll-end tuck top or tab lock closure. Printable inside and out. Starting at $0.65/unit for 1,000+.
Custom mailer boxes built for brands that ship direct-to-consumer. Made from 200gsm E-flute corrugated board (32 ECT rated), these boxes handle the rough transit of courier shipping while looking sharp enough for Instagram unboxing videos. Choose from roll-end tuck top, tab lock, or crash lock bottom construction — each designed for a different packing speed and product weight. Every surface is printable. Outside. Inside. Flaps. Tuck panels. Use CMYK offset for runs above 1,000 or digital printing for short runs starting at 500. Add spot UV on your logo, emboss a pattern into the lid, or go full matte lamination for that soft-touch feel brands like Glossier made famous. We manufacture mailer boxes from 3x3x2 inches up to 24x18x6 inches. Most DTC brands order between 9x6x3 and 14x10x4 — the sweet spot for apparel, cosmetics, and subscription products. Every box is sized to your exact product dimensions, cutting DIM weight charges and eliminating unnecessary void fill.
Custom mailer boxes are corrugated shipping containers designed specifically for e-commerce fulfillment. Unlike plain brown shippers, these boxes carry your brand artwork on every surface — converting a logistics expense into a marketing touchpoint that reaches 100% of your customers.
The standard construction uses E-flute corrugated board, measuring approximately 1.5mm thick with a 32 ECT (Edge Crush Test) rating. That translates to 32 lbs/inch of edge compression strength — enough to survive stacking, conveyor belts, and last-mile delivery vans. For heavier products (glassware, electronics), B-flute at 3mm thickness bumps the ECT to 42+.
Pricing scales with volume. Expect $4-6 per box at 500 units, $2-3 at 1,000, and under $1.50 at 5,000+. The biggest cost variable is not the box itself but the printing: single-color flexo on kraft is roughly 40% cheaper than full-color CMYK on white SBS liner. Interior printing (the surprise reveal effect) adds about $0.15-0.30/unit depending on coverage.
Three closure styles dominate the market. Roll-end tuck top (RETT) is the most popular — it gives a clean front tuck that stays closed without tape. Tab lock snaps shut mechanically, creating a tape-free opening experience. Crash lock bottom assembles in under 2 seconds, making it the go-to for fulfillment centers packing 500+ orders per day.
Need a deeper breakdown? Read our [Complete Guide to Custom Mailer Boxes](/blog/custom-mailer-boxes-ecommerce-guide) covering materials, closure types, printing methods, and 2026 pricing tables.
See how businesses across different sectors use this packaging
The mailer box IS the e-commerce experience. 72% of consumers say packaging influences their perception of a brand (Dotcom Distribution, 2024). Custom-printed mailers turn a commodity shipment into a branded unboxing moment.
Premium mailers with soft-touch lamination and rose gold foil match the luxury expected by beauty consumers. Custom die-cut inserts protect glass bottles during transit while presenting products in a salon-worthy display.
Tab-lock mailers in 14x10x4 inch format fit folded garments perfectly. Matte-laminated exteriors with embossed logos convey the brand story before the first button is touched.
FDA-compliant mailers with aqueous coating for specialty coffee, artisan chocolate, and meal kits. Kraft options with soy-based inks communicate farm-to-table authenticity.
B-flute corrugated (42 ECT) mailers with custom foam inserts protect gadgets up to 15 lbs. Anti-scratch coating on dark-colored boxes maintains pristine appearance through distribution.
Crash-lock bottoms speed up packing by 40% for high-volume subscription fulfillment. Full-color interior printing turns unboxing into a shareable social media moment.
Choose materials, printing, and finishing options
Premium 200gsm white-lined E-flute board with 1.5mm profile. Bright white surface delivers magazine-quality CMYK printing with crisp color reproduction and smooth ink coverage. 32 ECT crush resistance.
Natural unbleached kraft E-flute board with visible wood fiber texture. Ships the eco-friendly message before your customer even opens it. Works best with single-color or two-color flexo printing.
Heavy-duty 3mm B-flute board rated at 42 ECT for fragile or heavy items up to 15 lbs. The thicker flute cushions electronics, ceramics, and glass bottles during transit.
Made entirely from post-consumer waste fiber with soy-based inks. FSC-certified and fully curbside recyclable. Slightly speckled surface adds authentic eco character.
Ultra-smooth 350gsm clay-coated board for luxury brands. Delivers photographic print quality on par with retail shelf packaging. Best for cosmetics and premium goods.
300gsm duplex board with white printable face and grey recycled back. Cost-effective for mid-range brands needing good print quality without the full SBS price tag.
Ultra-thin 0.8mm profile for slim products like books, jewelry, and phone cases. Produces the smoothest print surface of any corrugated grade.
Lightweight hexagonal cell structure provides exceptional strength-to-weight ratio. 40% lighter than equivalent B-flute while maintaining crush resistance.
From concept to delivery in 4 simple steps
Share your requirements and get a detailed quote within 15 minutes during working hours. Our team reviews every project.
Receive a digital 3D mockup. Request unlimited revisions until you're 100% satisfied.
Your packaging enters production. Track progress through your dashboard in real-time.
Free shipping to your door. Standard delivery in 7-14 business days. Need it faster? Rush production delivers in 3-7 business days.
We offer sustainable alternatives for Custom Mailer Boxes that don't compromise on quality. Choose eco-friendly materials and printing options to reduce your environmental impact.
100% Recyclable
Made from recyclable materials
FSC Certified Options
Responsibly sourced materials
Soy-Based Inks
Eco-friendly printing
Carbon Neutral
Offset shipping available
Complete technical specifications for Custom Mailer Boxes
| MOQ | 500 units (digital) / 1,000 units (offset) |
| Material | E-Flute Corrugated Board (200gsm white SBS liner) |
| Printing | CMYK Offset, Digital, Flexographic |
| Finishing | Matte, Gloss, Soft-Touch, Spot UV, Foil Stamping, Embossing |
| Lead Time | 12-15 business days (7-8 rush available) |
| ECT Rating | 32 ECT standard / 42+ ECT heavy-duty |
| Size Range | 3x3x2 in. to 24x18x6 in. (custom dimensions) |
| Closure Types | Roll-End Tuck Top, Tab Lock, Crash Lock Bottom |
| Certifications | FSC, SFI, FDA-compliant options available |
| Board Thickness | 1.5mm (E-Flute) / 3mm (B-Flute) |
| Max Print Colors | Unlimited (CMYK) / 6 PMS spot colors |
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