Custom Mailer Boxes
Hale Path Packaging makes custom mailer boxes from printed corrugated board for USA ecommerce, subscription and retail brands. Each box is made to your dimensions, closes without tape, and can be printed on the outside, the inside or both. Choose your paper stock, print method, finish and an optional cardboard insert, then send us your product size and quantity for a quote.
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Custom Mailer Boxes Gallery
Why Brands Ship in Custom Mailer Boxes
A mailer box is a shipping box and a retail box in one. It protects the product on the way out and makes the opening feel intentional. Here is what you get:
- Tape-free closing. The front tucks in and the box stays shut, so customers open it cleanly.
- Print inside and out. Put your logo outside and a thank-you note, discount code or QR code on the inside lid.
- Made to your size. Less empty space means less filler and, often, lower postage.
- Corrugated construction. Corrugated board is sturdier than a thin folding carton, which helps the box hold up through carrier handling.
Choose Your Material, Print and Finish
Paper stock
Our mailer boxes are built from printed corrugated board, and you can choose kraft paper, art paper, card stock or recycled paper for the printed surface. Kraft gives a natural, earthy look and suits handmade and wellness brands. Art paper gives the smoothest surface for full-color artwork. Recycled paper is the choice if sustainability is part of your story; you can also browse our eco-friendly mailer boxes.
Print method
We print with offset, digital, UV and screen printing. In short: offset is the usual pick for larger runs and consistent color, digital suits shorter runs and detailed artwork, and UV and screen printing add punch for logos and special effects. Not sure which to pick? Tell us your artwork and quantity and we will recommend one. You can print the outside only, or the inside and outside.
Coatings and finishing
Matte lamination gives a calm, modern look. Gloss lamination makes colors pop. Soft touch feels smooth and premium in the hand, and UV coating adds shine and helps resist scuffs. For extra detail you can add embossing, debossing or foil stamping to your logo.
Flute: E-flute or B-flute
The flute is the wavy layer inside corrugated board. E-flute (about 1/16 inch) is thin and smooth, so it prints sharply and suits lighter items such as cosmetics, accessories and small electronics. B-flute (about 1/8 inch) is thicker and cushions better, which makes it a good fit for heavier or more fragile products. Tell us what you are shipping and we will point you to the right one.
Black, White, Kraft and Custom-Colored Mailer Boxes
Many brands pick a box color before they finalize artwork. A black mailer box gives a premium look, a white mailer box keeps branding clean, a natural kraft mailer suits earthy and handmade products, and full-color artwork turns the box into a brand statement. Tell us your color preference and quantity and we will confirm what is available for your order.
How to Get the Right Size
Sizing is the step that most affects fit and shipping cost. Do it in three steps:
- Stack your product as it will ship, including tissue, a card or an insert.
- Measure the inside stack as Length x Width x Depth, in inches.
- Add about 0.25 inch to each dimension (length, width and depth). That margin lets the product slide in and the lid close without bulging.
Carriers price packages by the space they occupy as well as by weight (dimensional weight), so a snug box can cost less to ship than an oversized one. Custom box sizes can be made to your product dimensions. If you are unsure, send your measurements through our contact page and we will check them.
Custom Mailer Boxes with Inserts
Fragile products need to stay in place. Pair your mailer with a cut-to-fit cardboard insert to hold bottles, jars, palettes or tubes. Browse our protective inserts and dividers, or tell us your product size and we will suggest a layout.
Who Uses Custom Mailer Boxes
- Subscription brands that want custom subscription box packaging with the same recognizable unboxing every month.
- Apparel and accessories sellers who want custom shipping boxes for clothing that match the quality of the product.
- Cosmetics and skincare brands that need a slim box with inserts for glass and tubes. See our custom cosmetic boxes.
- Candle and gift brands. Browse our candle mailer boxes and gift mailer boxes, or compare crash lock mailer boxes if you need a quick-assembly style.
- Ecommerce stores shipping direct to customers. See more ecommerce mailer boxes.
What to Include in Your Quote Request
To get an accurate quote, send us: product dimensions (L x W x D in inches), estimated quantity, preferred paper stock and flute, print method and number of colors, finish, insert requirements, and your artwork or a reference design.
Order Custom Mailer Boxes in 4 Steps
- Choose your packaging: size, stock, print and finish.
- Submit your quote request with dimensions, quantity and artwork.
- Review the details with our team, who check them with you.
- We produce and ship your order anywhere in the USA. See our shipping policy for details.
Request a quote for your custom mailer boxes with logo, or ask about wholesale quantities.
Frequently Asked Questions
What is the difference between a mailer box and a regular shipping box?
A mailer box is a shipping box and a retail box in one. It closes without tape, can be printed inside and out, and gives customers a branded unboxing. A regular shipping box is usually plain and made for transit only.
What is the minimum order quantity?
The quantities shown on this page start at 10,000 units. If you need a smaller run, send us your size and quantity through the quote form and we will tell you what is possible.
Can I print on the inside and outside of the box?
Yes. Choose outside only or inside and outside when you build your quote. Many brands print the logo outside and put a thank-you message, a discount code or a QR code on the inside lid.
Which print method should I choose?
Offset is the usual choice for larger runs and consistent color. Digital works well for shorter runs and detailed artwork. UV and screen printing add special effects. Send us your artwork and quantity and we will recommend one.
How do I measure for the right box size?
Stack your product as it will ship, measure the inside stack as length x width x depth in inches, and add about 0.25 inch to each dimension.
Can I add a cardboard insert to hold my product?
Yes. For fragile items such as glass bottles, jars or cosmetics we can add a cut-to-fit cardboard insert. Mention it in your quote request with your product size.
How does ordering work?
Submit your size, quantity and artwork, review the details with our team, approve the order, and we produce and ship it.
Do you ship across the USA?
Yes, we ship anywhere in the USA, including California. See our shipping policy for details.
How much do custom mailer boxes cost?
The price depends on five things: box size, paper stock, number of print colors, finish and quantity. Because every order is built to your specification, the quickest way to get an exact number is to build your quote on this page or send us your size and quantity.
How can I lower the cost per box?
Three changes make the biggest difference. Order a higher quantity, because the setup cost is spread over more boxes. Use fewer print colors or print the outside only. And choose a simpler finish, such as matte lamination instead of foil stamping. If you are searching for cheap custom mailer boxes, tell us your budget and we will suggest a setup that fits it without hurting protection.
What are the standard sizes, and can I get a custom size?
The standard sizes shown on this page are 5 x 4 x 1 and 6 x 5 x 2 inches. For anything else, choose a custom size in the quote form and enter your own Length x Width x Depth. You can enter inches, centimeters or millimeters.
What is the difference between matte, gloss and soft touch lamination?
Matte lamination has a flat, modern look and hides fingerprints. Gloss lamination is shiny and makes colors look brighter. Soft touch has a velvety feel that customers notice the moment they pick up the box. UV coating adds shine and helps protect against scuffs.
What artwork file do I need to send?
Upload your artwork with the quote form. Vector files such as AI or PDF give the sharpest print, but if you only have a logo image, send it anyway and our team will tell you whether it needs to be improved before printing.
What is the difference between E-flute and B-flute?
E-flute (about 1/16 inch) is thin and smooth, prints sharply and suits lighter items. B-flute (about 1/8 inch) is thicker and cushions better for heavier or more fragile products.
