Custom Mailer Boxes for DTC Brands and Ecommerce
Custom mailer boxes are the packaging of choice for direct-to-consumer brands, subscription services, and ecommerce businesses that want to deliver a memorable unboxing experience. At Teal Packaging, we design and manufacture printed mailer boxes that ship flat, assemble in seconds, and look incredible when your customer opens them.
Our mailer boxes feature a tuck-end closure that locks securely without tape, keeping your products safe during shipping. Built from 350gsm to 600gsm white or kraft paperboard (or E-flute corrugated for heavier items), these boxes strike the perfect balance between protection and presentation.
The Unboxing Experience Matters
Studies show that 40% of online shoppers share unboxing photos on social media. A plain brown box is a missed opportunity. Custom printed mailer boxes with your logo, brand colors, and interior printing turn every delivery into free marketing. Brands like Glossier, Dollar Shave Club, and Allbirds built cult followings partly through their packaging design.
We print on both the exterior and interior of the box. Popular options include a branded exterior with a surprise pattern, message, or instruction set printed inside the lid. Full-color CMYK, foil stamping, spot UV, and embossing are all available.
Mailer Box Styles
- Front Tuck Mailer: The classic ecommerce mailer. Opens from the front with a tuck flap. Sizes from 4"x4"x2" to 18"x12"x6".
- Roll End Tuck Top (RETT): Tucks on both ends for a clean, symmetrical look.
- Crash Lock Bottom Mailer: Auto-lock base for faster packing in high-volume fulfillment centers.
- Corrugated Mailer: E-flute or B-flute construction for products over 2 lbs. See our corrugated boxes page for heavy-duty options.
Perfect For
Subscription boxes (monthly snack, beauty, or hobby kits), clothing and apparel brands, cosmetics and skincare (pair with our cosmetic box inserts), artisan food products, tech accessories, jewelry, and corporate gift sets. If you sell online and ship to doorsteps, a custom mailer box is your best packaging investment.
Materials and Finishes
Choose from natural kraft (brown, eco-friendly look), white SBS paperboard (vivid color reproduction), or black paperboard for luxury brands. Finish options include matte lamination, gloss lamination, soft-touch coating, spot UV highlight, gold or silver foil stamping, and embossing or debossing. Recyclable material options and FSC-certified paper options are available by specification. Final claim language depends on selected board, coating, finish, and supplier documentation.
Ordering Details
MOQ: 100 boxes. Production time: 7 to 14 business days. Free shipping across the US. Custom sizes available in any dimension. Free design assistance from our in-house team.
Frequently Asked Questions
What size mailer box do I need?
Measure your product and add 0.5" to 1" on each side for padding. For apparel, 12"x9"x3" is a popular size. For cosmetics, 8"x6"x3" works well. For subscription boxes, 10"x8"x4" fits most configurations. We can produce any custom dimension.
Can I print on the inside of the mailer box?
Yes. Interior printing is one of our most popular options. Brands use it for welcome messages, social media handles, care instructions, or decorative patterns that surprise customers when they open the box.
Do mailer boxes need tape to close?
No. Our tuck-end mailer boxes have interlocking flaps that hold the box closed during shipping. For extra security with heavier items, a single piece of branded tape or a sticker seal works well.
What is the difference between kraft and SBS mailer boxes?
Kraft mailer boxes have a natural brown look that signals eco-friendliness. SBS (Solid Bleached Sulfate) is white paperboard that produces brighter, more vivid printed colors. Both are recyclable and available in 350gsm to 600gsm thicknesses.
How much do custom mailer boxes cost?
Pricing depends on size, material, quantity, and printing complexity. Mailer box unit pricing is quote-based and depends on dimensions, board grade, print coverage, interior printing, finish, inserts, and quantity. Full-color printed boxes with interior printing are quoted after confirming artwork, coverage, board, finish, and quantity. Contact us for an exact quote.
Custom Printed Mailer Boxes for Ecommerce and Subscription Brands
Custom printed mailers turn shipping packaging into a brand touchpoint. They are built for ecommerce orders, subscription boxes, influencer kits, apparel, cosmetics, small electronics, gifts, and direct-to-consumer product launches.
Mailer box options
- Inside and outside print, kraft or white liner, and full CMYK artwork
- Corrugated E-flute and B-flute options for shipping protection
- Eco-friendly printed mailer boxes with recyclable board and soy inks
- Custom inserts, dividers, sleeves, tape, and note cards
Related pages: custom printed boxes, kraft boxes, and subscription boxes.
Custom Printed Mailer Boxes for Ecommerce and Subscription Brands
Custom mailer boxes are built for branded shipping, product launches, subscription orders, influencer kits, and ecommerce unboxing. They can use corrugated board for protection, full-color print for brand recall, and inserts or dividers for better product presentation.
Branded mailer boxes can be kraft, white, black, or custom colored. For lower shipping cost, right-size the mailer around the product and check dimensional weight before ordering.
- Best uses: DTC orders, PR mailers, apparel, cosmetics, candles, food kits, gifts, and sample kits.
- Options: inside print, tear strips, inserts, dividers, label panels, matte or gloss finish, and retail-ready shipper displays.
- Sustainable choices: recycled corrugated, kraft board, right-sized structures, and water-based coating options where appropriate.
Are mailer boxes good for shipping?
Yes. Corrugated mailer boxes are made for ecommerce shipping, but fragile or heavy products may still need inserts, padding, or a stronger board grade.
Can I order colored mailer boxes?
Yes. Colored mailers can be made with printed flood coats, colored board options, or artwork designed around kraft or white corrugated board.
Use the dimensional weight calculator before production, then compare budget in the custom quote form.
