Custom Mailer Boxes
Engineered, printed, and converted directly at our manufacturing facility. Build a memorable unboxing experience with heavy-duty corrugated board, inside-and-out Pantone color reproduction, and factory wholesale rates starting at $0.48 per unit.
Explore Custom Mailer Box Styles & Configurations
Select a specialized structural style to fit your product's weight, dimensions, and unboxing format.
Tuck-Top Mailer Boxes
From $0.52/eaRoll-end front lock tabs for effortless opening and secure shipping.
Flat Mailer Boxes
From $0.39/eaSlim profiles optimized for apparel, prints, stationery, and thin merchandise.
Mailer Boxes with Inserts
From $0.85/eaCustom-cut corrugated partitions and precision molded foam inserts.
Apparel Sleeve Mailer Boxes
From $0.76/eaLuxury sliding outer sleeve paired with a durable shipping tray.
Printed Mailer Boxes
From $0.64/eaVibrant full-bleed interior and exterior printing with G7 color accuracy.
Die-Cut Mailer Boxes
From $0.72/eaCustom shapes, tamper-evident tear strips, peel-and-seal adhesive closures.
Corrugated Flute Grades & Material Options
Choosing the right flute ensures your mailer boxes resist edge crushing during courier handling while maintaining a smooth surface for razor-sharp printing.
E-Flute (ECT-32)
Featuring 90 flutes per linear foot, E-Flute produces an ultra-dense, flat surface with virtually no flute washboarding. Ideal for direct flexographic and digital printing.
- Best for: Subscription boxes & cosmetics
- Highest print resolution and ink holdout
- Weight recommendation: Under 12 lbs
B-Flute (ECT-44)
With 47 flutes per linear foot, B-Flute delivers greater thickness and superior vertical compression strength for heavier merchandise and drop protection.
- Best for: Glass bottles, hardware, shoes
- Enhanced puncture & corner impact defense
- Weight recommendation: 10 to 30 lbs
Coatings & Laminations
Add tactile luxury and scuff resistance. We apply coatings directly on our flexo press lines to preserve board recyclability while elevating the unboxing aesthetic.
- Matte Soft-Touch (Velvety tactile finish)
- Gloss Aqueous (Scratch & moisture barrier)
- Spot UV & Metallic Foil Stamping
Standard Custom Mailer Box Sizes
These proven dimensions fit common carrier dimensional-weight brackets (USPS, FedEx, UPS) while maximizing internal packing density. Custom dimensions are manufactured at identical wholesale rates.
| Size (L × W × D) | Internal Volume | Payload Capacity | Common E-Commerce Applications | Action |
|---|---|---|---|---|
| 6" × 4" × 3" | 72 cu in | Up to 5 lbs | Jewelry, cosmetics, soaps, small tech gadgets, skincare jars | Quote Size |
| 8" × 6" × 3" | 144 cu in | Up to 10 lbs | Soy candles, coffee bags, electronics, ceramic mugs, craft items | Quote Size |
| 9" × 6" × 2" | 108 cu in | Up to 8 lbs | Books, stationery kits, planners, jewelry collections, eyewear | Quote Size |
| 10" × 8" × 4" | 320 cu in | Up to 15 lbs | Subscription box kits, supplement bottles, curated gifts, food goods | Quote Size |
| 12" × 9" × 4" | 432 cu in | Up to 20 lbs | Folded apparel, hoodies, denim, shoes, luxury home accessories | Quote Size |
| 14" × 12" × 5" | 840 cu in | Up to 30 lbs | Multi-product bundles, winter outerwear, large retail shippers | Quote Size |
Configure Your Custom Mailer Boxes
Wholesale tiered pricing directly from the packaging floor. Receive an engineering review and guaranteed quote within 2–4 business hours.
Quote Request Received by Packaging Engineering
We are preparing your custom dieline template and wholesale volume rate breakdown. A packaging specialist will contact you at within 2–4 business hours.
Custom Mailer Boxes FAQ
Frequently asked questions about manufacturing minimums, dielines, and bulk production.
What makes custom mailer boxes the best packaging for e-commerce?
Custom mailer boxes are self-locking corrugated containers featuring double-folded side walls and roll-end front tabs (RETF). They assemble in seconds without tape or glue, withstand substantial transit vibration, and offer prime brand canvas on both exterior surfaces and inside the opening lid.
What is the minimum order quantity (MOQ) for custom mailer boxes?
Our production minimum is 500 units. Because we manufacture directly using high-speed rotary presses, 500 units represents the optimal price-break threshold where our factory-direct wholesale pricing significantly undercuts online packaging brokers.
Can I choose between natural kraft and white corrugated board?
Yes. We offer both 100% recycled Natural Brown Kraft (giving an organic, sustainable aesthetic) and Bleached White Kraft (which delivers maximum color pop and contrast for vibrant CMYK prints). Both boards are available in ECT-32 and ECT-44 ratings.
How do you handle custom sizing if our product does not fit standard boxes?
Because we operate in-house CAD sample cutting tables and automated rotary die-cutters, we can manufacture any custom length, width, and depth to within 1/16" tolerances. Our structural packaging team produces custom dieline templates for your designer within 24 hours at no additional fee.
What are your bulk wholesale price tiers?
Pricing scales efficiently with production volume. While a 500-unit run typically starts around $1.25–$1.60/box, orders of 2,500 units reach $0.62–$0.88/box, and enterprise volumes of 10,000+ units drop as low as $0.42–$0.56/box depending on print coverage.
Have a technical question about burst test ratings or dieline fitment?
Speak directly with a packaging engineer: 1-800-555-6245 or email sales@mailerboxfactory.com.