Corrugated Mailer Boxes are custom-printed, die-cut one-piece shipping boxes built from corrugated board for ecommerce brands that ship direct to customers without packing tape. You design the print, we manufacture it in the US.
The interlocking flaps fold closed and stay shut in transit, so your fulfillment team packs faster and your customer gets a clean unboxing instead of a tape-wrapped brown box. Add a printed interior and the inside of the lid becomes a branding moment the moment the box opens. A subscription brand shipping monthly product refills can run thousands of these through a fulfillment line with no extra sealing step.
Materials & Specifications
- Material: Corrugated board, E-flute for lighter goods or B/C-flute for heavier items
- Construction: Die-cut one-piece mailer with interlocking flaps, no tape required
- Printing: Full-color CMYK, print inside and outside
- Finishing: Matte or gloss lamination, custom inserts and partitions
- FSC option: FSC-certified paper available on request
Best Used For
- Ecommerce and direct-to-consumer order fulfillment
- Subscription box and monthly refill shipments
- Apparel, beauty, and consumer goods that need protection in transit
- Branded unboxing for repeat-purchase products
Printing & Finishing
Corrugated Mailer Boxes print in full-color CMYK across the exterior and interior. Upgrade with matte or gloss lamination for a more finished surface, or add die-cut inserts and partitions to hold product in place during shipping.
Why Order from Teal
We are a US-based custom packaging supplier with a 50-unit minimum on standard mailers. You get free design help, free US shipping, and full-color CMYK printing with an FSC-certified paper option. Choose rush service (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) or standard production from about 7 business days after proof approval. Order a sample kit ($50, credited to your first order), and we return every quote within 4 business hours.
FAQ
What's the minimum order quantity? The standard minimum is 50 units. Specialty rigid styles start at 100 or more, but corrugated mailers run at 50.
How long is production? Standard production runs from about 7 business days. A rush service (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) is available when you need stock sooner.
Can I get a sample? Yes. A sample kit is $50, credited to your first order so you can check board, print, and fit before a full run.
Are these recyclable? Corrugated board is widely recyclable, and FSC-certified paper is available on request.
Request a free quote and we'll get back to you within 4 business hours.
Corrugated Mailer Quantities in Practice
The classic mailer folds from one blank, with side wings that lock the walls upright and a front lip that keeps the lid shut in transit. E flute is the workhorse because it prints tightly while still absorbing a courier drop, and interior printing costs less than adding a separate sleeve.
| Mailer boxes | Ecommerce shipping tier notes |
|---|---|
| 50 | Photography samples and a first small customer batch. |
| 500 | Print coverage widens from a logo to full exterior artwork. |
| 1,000 | Tooling cost is fully absorbed and reorders get cheaper. |
| 5,000 | Three footprints for small, medium, and large orders in one lot. |
| 10,000+ | High volume ecommerce, priced through from about $0.44 per unit at volume. |
Set expectations around 7 business days for in-house eligible mailer output and as much as 12 weeks on specialty imported jobs, both approximate. Every US delivery is shipped at no charge to you. Start a quote by sending internal dimensions, board flute, print sides, and how many boxes you want.
How to Order Corrugated Mailer Boxes
Ordering custom corrugated mailer boxes is simple:
- Submit a quote request with your dimensions, quantity, and design references
- Receive quote guidance within one business day
- Send your artwork or work with our design team (free dieline + 2 revision rounds)
- Approve the digital proof and production begins
- Standard production runs from about 7 business days after proof approval; complex or high-volume orders take longer
