Custom Mailer Boxes
Self-locking ecommerce mailers with full exterior and interior brand print.
Our mailer program aligns E-flute or B-flute profiles with parcel weight targets and brand panels inside and out. Share fulfillment photos of how you pack today so locking tabs and lid clearances match your line.
Category: Mailer Boxes
Overview
Roll-end tuck front mailers sized to your SKU cube with optional interior floods, adhesive strips, and insert trays for DTC fulfillment.
Structure
Available styles
Specify the closure and panel layout that matches your fulfillment equipment and unboxing goals.
Style options
- • Roll-end tuck front
- • Tuck-top mailer
- • Self-lock bottom
Built-in features
- • Custom print inside and out
- • Size matched to your SKU
- • Prepress artwork review
- • Crush-resistant board options
- • Insert-ready layouts
- • Barcode-friendly panels
Customization options
Mix and match these levers when building your specification for quote review.
- Custom length, width, and height
- Exterior and interior print
- Material and caliper selection
- Spot UV, foil, or emboss accents
- Inserts, sleeves, and literature wells
- Versioned art for seasonal campaigns
Substrate
Materials
Board, film, and coating choices affect protection, print fidelity, and recyclability messaging.
- E-flute corrugated
- B-flute corrugated
- Kraft liner
- White liner
Brand execution
Printing options
Align color approach with substrate and run length before locking artwork.
- •CMYK full color
- •Spot Pantone colors
- •White ink on kraft
- •Interior print
Surface
Finishes
Coatings and accents protect panels in transit and reinforce premium cues at unboxing.
- •Matte aqueous
- •Gloss UV
- •Soft-touch laminate
- •Foil stamping
Industries we configure this for
These markets commonly specify this structure for protection, compliance, or presentation.
Artwork & prepress guidance
Following these steps reduces proof cycles and keeps scores aligned with your dieline.
- Design on production dielines with 1/8 inch bleed beyond trim.
- Keep barcodes and regulatory copy inside safe zones away from scores.
- Provide CMYK or spot colors with kraft-adjusted builds when using brown stock.
- Outline fonts and embed linked images in print-ready PDF handoff.
Specifications
- Typical lead time
- Varies by quantity and finish after proof approval
- Print methods
- Offset, digital, or flexo depending on substrate
- Minimum quantity
- Depends on style and tooling
- Freight
- Ships to US business addresses unless otherwise quoted
Frequently asked questions
Provide interior dimensions, quantity, print coverage, material preference, delivery state, and timeline. Attach dielines or reference photos if available.
Dual-sided print is common on mailers and rigid wraps. Note which panels need copy so prepress can plan plate or digital imposition correctly.
Sample units or prior production references may be available depending on schedule. Custom samples can often be produced for a fee after specifications are confirmed.
Matte aqueous coatings and laminates reduce scuffing during parcel handling. Soft-touch coatings change feel but may show fingerprints on dark panels.
Yes, if dimensions and structure stay constant you can swap print layers seasonally. Major size changes require a revised dieline and new proof cycle.
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Shop NowReady to specify Custom Mailer Boxes?
Move from exploration to a structured quote with dimensions, quantities, and artwork status.