White SBS Paperboard
Smooth white paperboard provides a clean surface for crisp printing and detailed graphics.
Ecommerce Packaging
Custom Mailer Boxes
A custom mailer box uses a single-piece structure with a locking closure that folds and secures into place, creating a durable format that holds its shape through handling and delivery. This makes mailer boxes a practical choice for parcel packaging and branded unboxing.
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By Structure
Mailer Box Structures
Mailer box structures are grouped by closure style. Explore the formats below to find the fold-and-lock design suited to your shipping needs.
Roll End Tuck Top Boxes
Rolled top edges reinforce the box while a tuck flap closes it.
Roll End Tuck Front Box
A front-tucking flap closes the box over reinforced rolled edges.
Roll End Boxes with Lid
A separate lid fits over the box's reinforced rolled edges.
Roll End 3 Flap Lock Box
Three interlocking flaps lock together over reinforced rolled edges.
By Style
Mailer Box Variants
Mailer box variants build on these structures with additional design options tailored to specific shipping and branding needs.
Corrugated Mailer Boxes
Corrugated board construction provides added strength for shipping protection.
Subscription Boxes
Recurring shipment format organizes multiple products into one branded package.
Candle Mailer Boxes
Mailer construction safeguards candles throughout parcel delivery.
Clothing Mailer Boxes
Protective mailers keep garments organized throughout transit.
Cosmetic Mailer Boxes
Mailer construction protects cosmetic orders throughout shipping and delivery.
Custom Apparel Mailer Boxes
Mailer construction protects folded apparel during shipping and delivery.
Jewelry Mailer Boxes
Protective mailers safeguard jewelry during shipping and delivery.
Perfume Mailer Boxes
Protective mailers reduce movement during perfume shipments.
Pharma Mailer Boxes
Protective mailers secure pharmaceutical shipments during transportation.
Build Your Box
Customization Options for Mailer Boxes
We provide customization options for mailer boxes, covering material, finish, and structural choices. Explore the options below to configure a mailer box suited to your product and brand.
Kraft Paperboard
Natural brown paperboard creates a sturdy carton with an earthy, uncoated appearance.
Recycled Paperboard
Recycled fiber paperboard forms a dependable carton with a naturally varied surface.
Corrugated Board
A fluted inner layer adds cushioning and structural strength for greater product protection.
Metallic Cardstock
Reflective metallic cardstock adds built-in shine without requiring separate foil stamping.
Holographic Cardstock
Rainbow-reflective cardstock shifts color under light for an eye-catching packaging surface.
Pearlescent Cardstock
Softly shimmering cardstock creates a refined, luminous finish across the packaging surface.
Textured Cardstock
An embossed tactile surface adds visible character before printing or decorative finishing.
Offset Printing
Metal plates transfer ink through rubber blankets, producing consistent, high-resolution results across larger production runs.
Digital Printing
Plate-free digital presses support shorter runs, faster setup, and variable artwork directly from production files.
UV Printing
UV inkjet systems print directly onto the surface and cure the ink immediately using ultraviolet light.
Screen Printing
A squeegee pushes ink through a stenciled mesh, creating bold color coverage and a dense ink layer.
Flexographic Printing
Flexible relief plates transfer ink efficiently across corrugated board, films, labels, and bags.
Gloss Lamination
A clear protective film creates polished shine, stronger color depth, and resistance against scuffs and handling.
Matte Lamination
A non-reflective protective film reduces glare while creating a smooth, refined, and understated packaging surface.
Soft-Touch Lamination
A low-glare protective film adds a smooth, velvet-like feel for a richer tactile packaging experience.
Aqueous Coating
A water-based coating provides light protection against scuffing and handling.
Embossing
Pressure raises selected artwork above the surface, adding tactile dimension without applying another material.
Debossing
Pressure recesses selected artwork into the surface, creating a precise and tactile indented impression.
Foil Stamping
Heat and pressure transfer metallic foil onto selected artwork for a sharp, reflective finish.
Spot UV
Clear gloss coating highlights selected artwork against the surrounding matte packaging surface.
Raised 3D UV
Layered clear UV coating builds glossy, dimensional details above the printed packaging surface.
Die-Cut Window with Clear Film
A shaped opening backed with clear film displays the product while keeping the packaging enclosed.
Open Die-Cut Window
An unlined shaped opening reveals the product directly with no transparent barrier across the window.
Handles
Integrated handles make packaging easier to carry in leather, plastic, or twisted rope. Available here: Plastic.
Tear Strip
A perforated pull strip removes cleanly to open the package without tools.
Pocket or Card Slot
An internal pocket holds instructions, certificates, cards, or other printed materials securely.
Tongue Lock
A shaped paperboard tab slots into place to hold the closure securely.
Ribbon Closure
A tied ribbon secures the box while adding an elegant, gift-ready opening detail.
Ribbon Lift
A fitted ribbon lifts the product from its insert for smooth, effortless removal.
Corrugated Inserts
Fluted inserts add cushioning, separation, and structural support inside mailer boxes.
Paperboard Inserts
Die-cut and folded paperboard platforms, dividers, and supports hold products securely in position.
Foam Inserts
Precision-cut EVA, PU, or EPE foam cushions products within secure, custom-fitted cavities.
Molded Pulp Inserts
Formed paper fibers create fitted, protective supports with a natural, lower-impact construction.
Thermoformed Plastic Inserts
Heat-formed PET or PVC trays create precise cavities that hold products securely in place.
Why Choose Custom Mailer Boxes
The value of a mailer box goes beyond holding a product. Its structure influences assembly, fit, durability through delivery, and the unboxing experience your customer sees first.
One-Piece, Locking Structure
Mailer boxes are built as a single piece with a locking closure that folds and secures into place, simplifying assembly.
Custom-Fit Dimensions
Each box can be sized to your product's exact dimensions, creating a snug, presentation-ready fit for parcel packaging.
Holds Up Through Delivery
The one-piece structure holds its shape through handling and delivery, keeping contents protected until they arrive.
Built for Branded Unboxing
The exterior surface supports full custom printing, turning the first opening into a branded experience.
How We Build
Mailer Boxes Manufacturing Process
Consult
Consultation
Product dimensions, weight, and shipping requirements.
Select
Structure Selection
Lock style, board weight, and internal layout.
Sample
Design & Sampling
A prototype is produced using your selected materials for approval before production.
Produce
Production
Printing, scoring, and die-cutting.
Inspect
Quality Check
Lock-fit strength, print alignment, and finish consistency.
Deliver
Delivery
Flat-packed and shipped to your location.
Frequently Asked Questions
What is a mailer box used for?
Mailer boxes are commonly used for parcel packaging and direct-to-customer shipping where a secure, branded box is needed.
Are mailer boxes recyclable?
Yes, most mailer boxes are recyclable depending on the board and finishes used.
What is the difference between mailer boxes and tuck boxes?
Mailer boxes use a one-piece, locking structure built for shipping durability, while tuck boxes close using folded, interlocking flaps.
Can mailer boxes be fully customized?
Yes, mailer boxes can be customized in size, structure, materials, printing, and finishes.
What closure types are available for mailer boxes?
Common closure types include Roll End Tuck Top Boxes, Roll End Tuck Front Box, Roll End Boxes with Lid, and Roll End 3 Flap Lock Box, each offering a different level of security and assembly speed.
Which printing methods can be used on mailer boxes?
Offset, digital, UV, and screen printing are available depending on design and volume.
What is the minimum order quantity?
Standard orders start at 50 units. Some specialized or fully custom structures may have different minimums depending on the design.
Can mailer boxes be used for branded, direct-to-customer packaging?
Yes, mailer boxes are commonly used for direct-to-customer orders where branded unboxing and secure delivery both matter.
Can I request samples before production?
Yes, samples can be produced before bulk manufacturing for approval.
Sample Kits
Feel the Packaging Before You Commit
Order a complimentary sample kit to see and feel our premium materials, custom finishes, and box styles in person.
Ships within 2 business days. You cover shipping. We cover everything else.
01
Material SwatchesKraft, coated paper, rigid board, and recycled polyethylene.
02
Printed SamplesSee foil stamping, embossing, spot UV, and matte lamination up close.
03
Structural DielinesFlat templates for mailer boxes, rigid boxes, tubes, and bags.
04
Finish ComparisonA side-by-side guide to gloss, soft-touch, and uncoated finishes.
Client Feedback
Words From Those Who Know Best
Packaging Dock transformed our unboxing experience. Our customers now share unboxing videos organically. Conversion on gift sets jumped 34%.
The grease-resistant pastry boxes were exactly what we needed. Our products arrive fresh and beautiful every single time.
We switched all our DTC shipping to their recycled mailers. Cost-neutral and our customers love the sustainability story.
The rigid box with magnetic closure turned our candles into a gift people actually want to give. Average order value doubled.
Their compostable valve bags keep our beans fresh for weeks while looking incredible on shelf. Wholesale accounts increased 28%.
From sample to full run, the turnaround was flawless. Their team thinks about packaging like a product, not just a container.
Start a Project
Let's Talk Packaging
Tell us a little about what you're looking to package, whether you already have specs or just an idea. We'll help you figure out the rest.
24hAverage quote response time
500+Brands partnered worldwide
50Unit minimum order quantity
7Day standard turnaround