Custom Mailer Boxes
The classic roll-end tuck-front mailer with full-color print inside and out, built for the unboxing moment.
- Self-locking, no tape required
- Full-color print inside and out
- Ships flat to save freight
In short
Custom mailer boxes are self-locking corrugated boxes printed with your logo, made for shipping straight to customers. Box Sense makes them to your size from 10 boxes, with production in 8–12 business days after proof approval. Shipping is free to any address in the USA.
About our custom mailer boxes
A mailer box is a corrugated box with a tuck-in front flap and locking side ears, the style known in the trade as a roll end tuck front (RETF) or FEFCO 0427. It assembles in seconds without tape, survives the courier network and opens like a gift, which is why it has become the standard box for e-commerce brands and subscription boxes.
We make mailers to your exact dimensions in white or kraft corrugated, printed outside, inside or both. Order from 10 boxes for a launch or a test, then scale to offset-printed runs of thousands with the same dieline.
Mailer box options
Choosing the board
| Board | Best for | Notes |
|---|---|---|
| E-flute, white or kraft | Most mailers up to about 10 lb | Thin and crisp with the best print surface |
| B-flute | Larger or heavier mailers | Thicker walls and more stacking strength |
| F-flute (micro flute) | Small, premium mailers | Very thin and smooth; closest to a rigid-box feel |
What affects the price of custom mailer boxes
Every box is made to order, so each order is quoted individually. These are the things that move the price most, in order:
- Size and flute. Larger mailers and thicker flutes (B-flute instead of E-flute) use more board.
- Quantity. Small runs are printed digitally; from a few hundred boxes, offset printing brings the unit price down sharply.
- Inside printing. Printing the inside adds a second print pass, though it is usually a small share of the total.
- Board color. White and kraft corrugated cost about the same; full color on kraft needs a white ink base.
- Extras. Inserts, tear strips, peel-and-seal tape and special finishes add to the unit price.
Send your size, quantity and artwork through the quick quote form for a firm price within 24 hours.
Getting the size right
Measure the inside dimensions you need (length, width and depth of the product or kit), then add a few millimeters of clearance and room for any tissue or insert. We engineer the dieline around those inside dimensions and allow for the board thickness, so the box closes cleanly without bulging.
A right-sized mailer protects better and can reduce dimensional-weight shipping charges, which carriers bill on the outer size of the box.
Built for unboxing
- Inside printing for a reveal message, pattern or QR code
- Custom inserts so nothing rattles in transit
- Tear strips and peel-and-seal adhesive for return-ready mailers
- Soft-touch, spot UV and foil finishes on the outer print
How ordering works
- Send your specs. Product size, quantity and artwork (or just a logo). A packaging specialist replies with a firm quote within 24 hours.
- Approve the proof. We send a dieline and a 3D proof so you can see the box before it is made.
- Production. 8–12 business days in our own facility, or 5 days on rush.
- Delivery. Boxes ship flat to you anywhere in the USA, free of charge.
Frequently asked questions
What is the minimum order for custom mailer boxes?+
10 boxes. Short runs are printed digitally with no plate charges; larger runs move to offset printing for a lower unit price.
Do mailer boxes need tape?+
No. The front flap tucks in and the side ears lock, so a mailer closes securely on its own. Many brands add a branded sticker or a peel-and-seal strip for tamper evidence.
Can you print on the inside of the mailer?+
Yes. Inside printing is one of the most popular upgrades. It is printed on the same sheet, so it adds little to the cost compared with the impact it has on unboxing.
Are mailer boxes strong enough to ship without an outer box?+
Yes, that is what they are designed for. For heavier or fragile products we move up from E-flute to B-flute or add an insert.
How long does production take?+
8–12 business days after you approve the proof, with a rush option of 5 business days.
Related products
PopularSubscription Boxes
Kraft Mailer Boxes
White Mailer Boxes
Tuck Top Mailer Boxes
Let's build your custom mailer boxes.
Tell us what you are packing. You will have a quote, a free dieline and a sample plan within 24 hours.