Custom Mailer Boxes
These boxes are easy to assemble and have a tab lock tuck feature that keeps your item protected, ready for mailing to your customers. Now don't need to send plain boxes to your customers when you have a good choice to wow them with' custom mailer boxes choosing from us. Made to your size and artwork from 100 units, with the die, plates, design support and US shipping included, and a digital proof before anything prints.
Key Takeaways
iBox Factory makes custom mailer boxes from 100 boxes per size and artwork. Mailer boxes are quoted by internal dimensions, because the inside size has to clear your product plus any protective packing. The die, the plates, design support and US shipping are included, and you approve a digital proof before anything prints.
More Eco Friendly Boxes we make
Every style below is made to your size and artwork, from 100 units.
Custom Packaging That Defines Your Brand
Get Your Packaging Details Right
Shipping, materials, and finishes are chosen per job so the box fits your product and your budget.
Shipping
Free shipping across the US on every order. Choose the lane on your quote: Rush (expedited production plus air freight), Standard (air), or Cost Saver (sea).
Materials
Pick the board for the job: kraft, coated paperboard, corrugated for shipping strength, or rigid chipboard for a premium unboxing. FSC-certified paper stock and soy-based inks.
Add-Ons and Finishes
Matte or gloss lamination, foil stamping, embossing, spot UV, windows, and inserts. Ask on the quote and we will price the combination.
Five Steps to Your Packaging
We handle it from the first idea to the box at your door.
Request a Quote
Tell us style, size, quantity, and printing. We come back with a written quote.
Finalize Your Design
Send artwork or work with our designers. The die and plates are included.
Approve Your Order
Check the quote and the digital proof. Nothing prints until you sign off.
Production
Printed, finished, and inspected against your approved proof.
Delivery
From about 7 business days of production, plus 2 to 5 for delivery, on the lane you chose.
Quote in Minutes
Attach artwork or a reference image if you have one. We reply with a written quote and a proof.
A mailer box is a one-piece corrugated box that folds up without tape and closes with a tuck flap. It is the format most ecommerce brands mean when they say "custom box", because it prints well on the outside, opens cleanly in front of a customer, and does not need a second shipping carton around it.
Three mailer styles
| Style | Closure | Best for |
|---|---|---|
| Roll end tuck top | Front tuck flap that folds over the top | The general purpose ecommerce mailer, strongest of the three |
| Roll end front tuck | Tuck flap that closes into the front panel | A cleaner front face when the top panel carries the artwork |
| Die cut mailer with dust flaps | Tuck plus side dust flaps | Smaller items where dust and edge protection matter |
Getting the size right
Mailers are quoted by internal dimensions, in the order length by width by depth, with length being the longest side of the opening. Measure the product as it will actually sit in the box, then add clearance for whatever protects it: tissue, a paper wrap, an insert, void fill. A quarter inch of total clearance is nothing once a foam sheet goes in. If the product is fragile or oddly shaped, a fitted insert usually costs less than the returns caused by a box that lets it move. See insert packaging for the options, and mailer box dimensions for the common footprints.
Oversized boxes cost twice: once in board and once in dimensional weight from your carrier. Shaving an inch of depth off a mailer you ship thousands of times a year is usually the single largest saving available on the whole job.
Flute choice
E flute is roughly a sixteenth of an inch thick and has a fine surface that takes detailed print well, which makes it the usual pick for a retail-facing unboxing mailer. B flute is about an eighth of an inch and gives more crush resistance for heavier or denser items at some cost in print fineness. If you are not sure, tell us the shipped weight and the fragility and we will spec it. Background on the structure is in what is flute in corrugated.
Printing inside the box
Interior print is the cheapest theatre in ecommerce packaging, but it is not free: it is a second print surface and it is quoted as such. A single interior color on the base panel usually reads as strongly as full interior coverage at a fraction of the cost. Whatever you choose, you see it on the digital proof before anything runs.
Minimum, price and lead time
The minimum is 100 boxes per size and artwork. Pricing starts from about $0.48 per unit at bulk volumes, confirmed in writing. The cutting die, the printing plates, design support, US shipping and a digital proof are included. Turnaround is stated per product across three lanes: rush combines expedited production with air freight and adds roughly 7 to 25 percent, standard moves by air, and cost saver moves by sea. Production runs from about 7 business days plus 2 to 5 days for delivery, and specialty imported items can go up to about 12 weeks.
Send your product dimensions and monthly volume to the quote form and we will quote two or three size options rather than one. If you also ship larger orders in an outer carton, see custom shipping boxes.
