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. All materials are recyclable and sourced from FSC-certified suppliers.
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. Small kraft mailer boxes (8"x6"x3") with single-color exterior printing start around $0.80 to $1.50 per unit at 500 quantity. Full-color printed boxes with interior printing range from $1.50 to $4.00 per unit. Contact us for an exact quote.
