Die Cut Mailer Boxes are one-piece corrugated shipping boxes for ecommerce brands that want their packaging cut to a custom shape and printed in full color. Each box is die-cut from a single sheet of corrugated board, so it folds flat for storage and snaps together at the bench without tape or glue.
Because the box is cut precisely to your product profile, items sit snug in transit and arrive with less rattle and fewer dents. The interlocking flaps give a clean unboxing moment that photographs well for repeat customers, while the flat-pack design keeps your storage footprint and freight costs down. A subscription box brand, for example, can ship a tightly fitted mailer that doubles as branded shelf-ready presentation on arrival.
Materials & Specifications
- Material: Corrugated board, E-flute for lighter goods or B/C-flute for heavier weights
- Construction: One-piece die-cut mailer with interlocking front and side flaps, no tape needed
- Printing: Full-color CMYK, inside and outside
- Finishing: Matte or gloss lamination, custom inserts and partitions
- Sustainability: FSC-certified paper available on request
Best Used For
- Ecommerce and direct-to-consumer order fulfillment
- Subscription boxes and curated gift sets
- Apparel, beauty, and small electronics shipping
- Retail kits that need a custom-shaped fit around the product
Printing & Finishing
Print Die Cut Mailer Boxes edge to edge in full-color CMYK, and add a printed interior so the box reveals your brand the moment it opens. Choose matte lamination for a soft, fingerprint-resistant surface or gloss for higher contrast and shelf pop. Custom inserts and partitions hold multiple items in place during shipping.
Why Order from Teal
Teal is a US-based custom packaging manufacturer, so your boxes are made and shipped domestically with free US shipping. Order from a MOQ of 50 units, get free design help, and choose 5-day rush or 7-business-day standard production. Every box prints in full-color CMYK with an FSC-certified paper option, and a free sample kit ships for just $19.99, credited to your first order. Quote requests get a reply within 4 business hours.
FAQ
What's the minimum order quantity? The standard minimum is 50 units, which keeps custom corrugated mailers practical for growing brands.
How long is production? Standard production runs 7 business days, with a 5-day rush option when you need boxes sooner.
Can I get a sample? Yes. A free sample kit (just $19.99 shipping) lets you check the board, fit, and print, and the cost is credited to your first order.
Request a free quote and we'll get back to you within 4 business hours.
How to Order Die Cut Mailer Boxes
Ordering custom die cut 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 takes 7 business days after proof approval; complex or high-volume orders may require 10-14 business days
