Mailer boxes do two jobs at once: they survive the carrier network and they are the first physical thing a customer sees of your brand. That dual role is why they are specified differently from a plain shipper. To order, go to mailer boxes.
Anatomy, so the terms on your quote make sense
The common style is a one-piece roll end tuck top. The base is formed by rolled side walls that give the box a doubled edge, and the lid is a single hinged panel with a front tuck and two side wings that lock it. No tape, no glue, and the customer opens it by lifting one flap. Variants change the lid: a roll end front panel adds a printed face that folds down, a tuck front adds a locking front tab, and a double-wall mailer adds thickness at the walls for heavier goods.
Sizing, and the dimension people get wrong
- Build the packed unit, including any tissue, card, void fill and the invoice.
- Measure it at its widest in each axis.
- Add the cushion thickness on each face it touches.
- Set the depth last and set it honestly. Depth is where mailers get oversized, because a shallow box feels risky. It is the dimension that costs you most in dimensional weight, and the arithmetic is on dimensional weight.
- State the result as internal length x width x depth and ask for written confirmation that it is internal.
If your order profile varies, two or three mailer sizes almost always beat one box sized for the largest order. The die is included, so having a second size costs tooling nothing.
Board choice
| Board | Approximate caliper | Use |
|---|---|---|
| E flute | About 1/16 in | The mailer default. Folds crisply, takes fine print, keeps the box slim. |
| B flute | About 1/8 in | Heavier contents, more crush resistance, a slightly chunkier fold |
| Double wall | Thicker again | Heavy or high-value goods where the mailer is also the only protection |
Send the packed weight of one box and we will match the grade to it rather than guessing from the footprint.
Print: the inside is the point
On a plain shipper the outside is everything. On a mailer, the outside spends its life on a truck and the inside is revealed at the moment the customer is paying most attention. That makes interior print, a printed lid underside, or a short message on the inner base the highest-return decision on the box. Exterior options range from one colour on natural kraft, which is cheap and reads as deliberate, to litho-laminated full coverage for photographic quality.
Features worth specifying up front
- Tear strip for an easy first open, which also gives a clean edge rather than a torn one.
- Double adhesive strip so the same box can be resealed for a return, which removes a step from your returns process.
- Insert or platform if the product should be presented rather than just contained.
- A second, smaller size for your lighter orders, decided at the same time so both dies are made together.
Minimums, price and lead time
The minimum is 100 boxes and pricing starts from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before anything prints are included. We make in two plants, West Chicago in the US and Guangzhou in China, and turnaround is quoted per product in three lanes: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days plus 2 to 5 for delivery.
Order at mailer boxes. If your product is soft and compressible, compare the cost against poly mailers before committing to a rigid box.
Send your packed load dimensions, the packed weight and whether you want interior print through the quote form, and we will come back with an internal dimension, a board grade and a written price.
