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Mailer · 23 styles

Custom Mailer Boxes For E-Commerce, Subscriptions & PR Kits

Ship products safely and deliver an unboxing your customers want to share. Our custom mailer boxes are made from strong corrugated board, printed inside and out with your brand, and sized to your products so they arrive protected, with less filler and lower shipping costs.

  • Roll-end tuck-front, self-locking, tab-lock and ribbon-tie styles
  • Inside & outside printing, inserts and tamper-evident options
  • Free design support with a 3D mockup
4–5 day production Free design support Businesses & individuals From $0.20 per item
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Popular: Apparel Mailer Boxes Candle Mailer Boxes Corrugated Subscription Mailer Boxes Cosmetic Mailer Boxes Die Cut Window Mailer Boxes
Custom Mailer by The Packaging Masters
Free Design3D mockup included
4–5 Day Productionafter proof approval
23Mailer styles
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All Mailer Styles

Every style in this category with its starting price per item. Open any product to see sizes, materials and finishes, then add it to your cart or request a free quote.

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Order Custom Mailer Boxes In 6 Simple Steps

  • Choose Your Mailer Style icon
    Choose Your Mailer Style

    Tuck-front, self-locking, tab-lock, ribbon-tie or tamper-evident.

  • Share Product Size & Weight icon
    Share Product Size & Weight

    Item dimensions, weight and how many go in each box.

  • Pick Board & Insert icon
    Pick Board & Insert

    E-flute or B-flute corrugated, white or kraft, with inserts.

  • Send Artwork icon
    Send Artwork

    Outside and inside designs, or free help from our designers.

  • Approve Proof & 3D Mockup icon
    Approve Proof & 3D Mockup

    See your mailer in 3D before production.

  • Production & Delivery icon
    Production & Delivery

    4–5 business days production, then 5–7 business days shipping.

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How We Work

After You Approve The Quote,
Here’s What Happens Next.

From approval to doorstep — handled end to end.

Every order runs through four specialist teams — structural design, print, finishing, and dispatch — so your packaging keeps moving without bottlenecks, delays, or guesswork.

  • A dedicated team at every single stage
  • Live status updates from start to finish
  • Clear timelines, delivered on schedule
01

Finalize your design

Sizes, materials, finishes, and artwork are locked in. You review the proof carefully and approve when every detail matches your brief.

02

Print & production

Your job moves to print, cutting, lamination, and finishing. Our production team monitors color, registration, and structural accuracy.

03

QC, packed & sealed

Finished boxes are checked against the approved sample, counted, and securely packed to protect edges and print during transit.

04

Track & receive

Dispatch shares tracking details so your team can plan filling and launch dates. Your packaging arrives press-ready and production-ready.

Why Custom Mailer Boxes Are the Heart of E-Commerce Packaging

For online brands, the mailer box is the store, the shelf and the first handshake rolled into one. Custom mailer boxes protect your products through courier networks and create a branded unboxing moment that encourages reviews, repeat orders and social sharing. Compared with plain shipping cartons, printed mailers look intentional, close securely without tape and present products neatly when opened.

  • Protection: corrugated walls and inserts absorb knocks and drops.
  • Branding: printed outside and inside for a premium reveal.
  • Efficiency: right-sized boxes reduce filler and dimensional-weight shipping costs.
  • Loyalty: a memorable unboxing turns customers into fans.

Wingless Flapless

Mailer Box Styles Explained

Style How it closes Best for
Roll-end tuck-front Front tuck flap, dust flaps Subscriptions, apparel, cosmetics
Self-locking mailer Interlocking flaps, no tape Fast packing, e-commerce volume
Tab-lock / cherry-lock Locking tabs on the sides Heavier items, secure closure
Ribbon-tie mailer Satin ribbon closure Gifts, PR and luxury kits
Tamper-evident mailer Tear strip and seal High-value or sensitive products
Two-piece shipper Separate lid and base Premium presentation that ships

See ready-to-customize options like self-locking mailer boxes, tab-lock mailer boxes, ribbon-tie mailer boxes and tamper-evident security mailers.

Tamper Evident Security

Corrugated Board Strength: Flutes and ECT Made Simple

Mailer boxes are made from corrugated board: a fluted middle layer glued between two liners. The flute size and board grade decide how strong the box is.

Board Thickness Best for
E-flute About 1/16 inch Most mailers, crisp printing, light to medium items
B-flute About 1/8 inch Heavier products, extra crush protection
Double-wall (E/B) About 3/16 inch Very heavy or fragile shipments

ECT (Edge Crush Test) measures how much stacking pressure a box can take; a higher ECT means a stronger box. Most e-commerce mailers use 32 ECT board, with stronger grades for heavy items. Tell us your product weight and we will recommend the right board.

Self Locking Mailer

Inside and Outside Printing for Unboxing Moments

Outside printing makes your parcel recognizable on the doorstep; inside printing creates the reveal. Popular ideas include a bold logo outside with a clean minimal look, a full-color pattern inside, a thank-you message under the lid, social handles, a QR code to tutorials or a reorder link, and a discount code for the next purchase. White boxes show colors brightly, while kraft boxes look natural and can be printed with white ink for contrast.

Tab Lock Mailer

Inserts That Keep Products in Place

  • Corrugated inserts – strong, recyclable cavities for bottles, jars and devices.
  • Paperboard inserts – neat presentation for cosmetics, accessories and kits.
  • Foam inserts – maximum protection for electronics, glass and high-value items.
  • Dividers and platforms – organize multi-product subscription boxes.

Satin Ribbon Tie

How to Size a Mailer Box (and Save on Shipping)

Measure your product or packed kit: length, width and height, plus any insert or tissue. Add a small clearance, about 1/8 to 1/4 inch per side, so items fit snugly without crushing. Couriers often price by dimensional weight, so a right-sized mailer can lower shipping costs on every order. Share your measurements and we will calculate the inner size and show it on a free 3D mockup.

Roll Over Flap Tuck Front

Subscription Boxes, PR Kits and Influencer Packaging

Subscription brands need a consistent box that still feels exciting every month; PR and influencer kits need a “film-worthy” reveal. Combine a printed mailer with custom inserts, tissue, a welcome card and a printed inside lid. You can keep one structure and change inside artwork or sleeves for seasonal drops and campaigns.

RETF (Roll End Tuck Front)

Eco-Friendly Mailer Boxes

Corrugated mailers are widely recyclable, and kraft board offers a natural, sustainable look. Use water-based inks and coatings, paper-based inserts and paper tape, and print recycling guidance inside the lid. Right-sizing reduces material and filler, which is good for the planet and your shipping budget.

RETT Mailer Boxes

Artwork Tips for Printed Mailer Boxes

  • Use our dieline: we provide a flat template showing panels, folds and glue areas for your size.
  • Add bleed: extend backgrounds about 1/8 inch past the cut lines.
  • Keep a safe zone: place logos and text away from folds and edges.
  • Use vector logos (AI, EPS, SVG or PDF) and high-resolution images (300 dpi).
  • Set colors in CMYK, or give Pantone codes for exact brand colors.
  • Check orientation: remember which panels face up when the box is closed and when it opens.

Not a designer? Our team offers free design support and will prepare print-ready artwork and a 3D mockup for you.

Promotional Kit Mailer Boxes

Common Mailer Box Mistakes to Avoid

  • Oversized boxes that need lots of filler and raise dimensional-weight shipping costs.
  • Board that is too light for heavy products, causing crushed corners.
  • No insert for fragile items like glass bottles or electronics.
  • Important text on folds where it cracks or disappears.
  • Forgetting the inside – the reveal is where most unboxing photos are taken.

Peel and Seal Adhesive Strip Mailer Boxes

Mailer Boxes for Every Industry

We make mailers for apparel and accessories, beauty and skincare, supplements, candles and home fragrance, electronics, books and stationery, food gifts and more. Pair them with product packaging from our custom cosmetic boxes, custom candle boxes and custom gift boxes for a complete branded experience.

Matte Black Finish Mailer Boxes

Why E-Commerce Brands Choose The Packaging Masters

  • Sized to your products: mailers and inserts built around what you ship.
  • Free design support and a 3D mockup before production.
  • Fast turnaround: 4–5 business days production after proof approval, then 5–7 business days shipping across the USA and Canada.
  • Open to everyone: startups, online stores, subscription brands and individuals, from small runs to wholesale volumes.
  • Made-right promise: free reprint or refund if your order arrives defective or incorrect.

Browse all packaging categories to match your mailers with product boxes.

Customer Reviews & Testimonials

Real Success Stories from Happy Clients

“Perfect for Shipping Books”

These wingless flapless mailer boxes are ideal for our bookshop. Dropping the dust flaps gave us noticeably more interior space, so our hardcovers fit snugly without a bigger box. They pack faster too, which sped up our fulfillment. The built-in inner cover keeps books pristine. A smart, space-efficient packaging upgrade.

Harold Bennett
“Efficient Custom Sizes”

The design team built custom sizes that fit our shoe boxes perfectly with more usable space than our old mailers. Using less material trimmed our cost per unit, and the ear-lock closure holds securely. Our bulk order arrived early and free design support was excellent. Streamlined, economical, and reliable packaging.

Melissa Tran
“Fast Packing Favorite”

Fewer flaps means our team assembles these mailers noticeably faster, which matters when we ship binders and literature in volume. The flapless tuck-top is self-sealing and clean, and the full-color print looks sharp. They convert nicely to display boxes too. This streamlined design genuinely improved our packing efficiency.

Curtis Nwosu
All Reviews

  • A mailer box is a printed, self-closing corrugated box designed for presentation and shipping in one. A plain shipping carton usually needs tape and is not designed for unboxing.

  • E-flute is the most popular for mailers because it is strong and prints crisply. B-flute or double-wall board is better for heavy or fragile products.

  • ECT stands for Edge Crush Test. It measures how much stacking pressure the board can handle; a higher number means a stronger box.

  • Yes. We print outside, inside or both, in full color or Pantone, on white or kraft board.

  • Yes. White ink on kraft gives a natural look with strong contrast for logos and text.

  • Yes. We make corrugated, paperboard and foam inserts with cavities for your products.

  • Measure your product or kit, add about 1/8 to 1/4 inch clearance per side, and share the details. We will calculate the inner size and show it on a 3D mockup.

  • Our corrugated and kraft mailers are recyclable, and we offer water-based inks, paper inserts and recycling guidance printed on the box.

  • Production takes 4–5 business days after proof approval, and shipping takes 5–7 business days within the USA and Canada.

  • Yes. Startups, small online stores and individuals can order small runs, and growing brands can order wholesale volumes.

More FAQs
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Open To Everyone

Businesses and individuals can order.

4–5 Day Production

After proof approval, then 5–7 day shipping.

Free Design Support

Help with artwork and 3D mockups.

Made Right Promise

Free reprint or refund for defects.

About The Packaging Masters

Packaging Built For
Brands That Care
About Details

Instead of generic stock boxes, every project starts with your product, your goals, and your customer experience — so the packaging protects in transit and still feels premium in hand.

Get A Free Quote Contact Us
Custom — Not Catalogue

Built to your product, not pulled from a shelf of ready-made sizes.

Premium Look, Real Protection

Strong structures, neat edges, and finishes that actually sell.

Open To Everyone

Businesses and individuals can order — start with a small run and scale when you’re ready.

Fast, Clear Timelines

4–5 business days production after proof approval — you always know what’s next.

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