Packaging style
Custom mailer boxes
The workhorse of e-commerce. Roll-end tuck-front (RETF) and roll-end tuck-top mailers ship flat, assemble without tape and print edge-to-edge inside and out.
Mailer Boxes in our catalog
13 products use this structure.
PopularCustom Mailer Boxes
The classic roll-end tuck-front mailer with full-color print inside and out, built for the unboxing moment.
PopularSubscription Boxes
Monthly-box mailers sized to your kit, with inside print, tissue and inserts that keep subscribers sharing on social.
Kraft Mailer Boxes
Natural brown corrugated mailers printed with one-color or white ink for a clean, sustainable look.
White Mailer Boxes
Bright white corrugated mailers that make color pop, ideal for beauty and fashion brands.
Tuck Top Mailer Boxes
Roll-end tuck-top mailers with a front tuck flap and optional tear strip for a clean, secure closure.
Book Mailer Boxes
Slim wrap-around mailers that hug books, planners, frames and prints to prevent corner damage.
Corrugated Boxes
E, B, C and double-wall corrugated boxes engineered for protection, stacking strength and print quality.
PopularCustom Kraft Boxes
Natural brown kraft paperboard and corrugated boxes printed with your logo, from retail cartons to mailers.
PopularEco-Friendly Boxes
Recycled-content boxes printed with soy inks and finished with plastic-free aqueous coatings.
Apparel Boxes
Garment boxes, magnetic gift boxes and branded mailers for clothing and accessories.
T-Shirt Boxes
Slim mailers and folding boxes sized for folded tees, with tissue and sticker options.
Pet Food & Treat Boxes
Barrier pouches, cartons and subscription mailers for treats, food and toys.
Corporate Gift Boxes
Welcome kits and client gifts with custom inserts, sleeves and branded tissue.
In short
A mailer box is a die-cut corrugated box with a hinged lid that locks shut without tape. It is the standard box for e-commerce and subscription orders. Box Sense makes mailer boxes in any size from 10 boxes, printed outside, inside or both.
The mailer is popular for one reason: it protects like a shipping box and opens like a gift. The lid folds over, the front flap tucks into the walls, and the double side walls stiffen the whole box.
It ships flat and folds by hand in a few seconds, which keeps packing fast as orders grow.
How to specify a mailer box
- Inside size. Give length, width and depth of the space your product needs, in that order.
- Board. E-flute is thin and prints sharply, and suits most products. B-flute is thicker for heavier or fragile items.
- Color of board. White gives bright color. Kraft gives a natural look and hides scuffs.
- Print sides. Outside only keeps cost down. Inside print adds the reveal.
Where to start
- Custom Mailer Boxes: the full-color standard for brands.
- Kraft Mailer Boxes: natural board with one-color or full-color print.
- White Mailer Boxes: a clean white base for bright artwork.
- Subscription Boxes: mailers planned around a monthly reveal.
- Tuck Top Mailer Boxes: a tuck-top variant for retail and gifting.
When a mailer is the wrong box
Above roughly 15 to 20 pounds, or for large items, a taped shipping box is stronger and cheaper. For light retail products on a shelf, a folding carton costs less. A mailer sits between the two.
FAQ
Do mailer boxes need tape?+
No. The front flap locks into the side walls. Some brands add a sticker or tape strip as a tamper seal.
Can mailer boxes ship without an outer box?+
Yes. They are made to be the shipping container. Fragile contents need an insert.
What is the minimum order?+
10 boxes. Short runs are printed digitally, and larger runs move to offset printing for a lower cost per box.
Ready to make packaging that sells?
Tell us what you are packing. You will have a quote, a free dieline and a sample plan within 24 hours.