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Custom Mailer Boxes
Quantity per-unit price drops as you scale
Standard production runs from about 7 business days after proof approval (complex or high-volume orders take longer), plus 2-5 days US delivery. You approve a digital proof before anything prints.
PDF, AI, EPS, PNG, JPG, TIFF, or PSD · up to 25 MB · 300 dpi recommended
Custom size, 20k+ units, or a spec you don't see? Request a quote →
Key Takeaway
Teal Packaging sells custom printed mailer boxes online at tealpackaging.com/shop/custom-mailer-boxes/ with live per-unit pricing from $1.36 per box and instant checkout.
Online orders start at 150 boxes; smaller runs from 50 units and custom sizes are available through a custom quote. Every order includes free US shipping, free dieline design, and a digital proof, with production from about 7 business days after proof approval (complex or high-volume jobs take longer).
Free design support, always
Real designers on our US team prep your artwork at no charge.
- Free custom dieline built to your exact spec
- Free artwork setup, bleeds, and print-ready check
- Digital proof before we print, two revision rounds
- No design fees, no hidden charges, ever
- No print-ready file? Send a logo, we handle the rest
- Nothing goes to print until you approve the proof
What happens after you order
You pay on this page at the per-unit price shown for the quantity you picked. After that:
- Digital proof. We put your artwork on the actual dieline and send it back for approval. Nothing prints until you approve it, and dieline design is free on every order.
- Production. In-house items run from about 7 business days after proof approval. Specialty imported items can run up to about 12 weeks. If you have a date to hit, tell us before you order and we will confirm what is realistic.
- Delivery. US shipping is free, plus 2 to 5 business days in transit once your order ships.
We can hold the stock and ship it for you
The default is that every carton lands at your door and you find somewhere to put it. There is another option. Your finished packaging can go to Teal's fulfillment center in West Chicago, Illinois instead, and stay there until it is needed.
From that warehouse we can:
- Warehouse your packaging and release it in batches, so you can buy at volume pricing without renting space for the pallets
- Kit and assemble: your product, your packaging, inserts, cards, samples, whatever goes inside
- Pick, pack and ship orders as they come in
- Ship to individual recipients, so one order from you can reach hundreds of separate addresses
That last line is the one worth rereading. If you are sending a subscription box, a welcome kit, event swag or client gifts, you send the address list and we ship each package. You never touch a box.
Worth asking about if
- You are ordering more packaging than you have room to store
- Your orders go out to many addresses rather than back to one of yours
- You ship the same kit again and again: monthly boxes, onboarding kits, seasonal gifts
- Packing orders by hand is eating time you would rather spend selling
How to start
Buy this product now and add fulfillment later. None of it has to be decided at checkout. When you are ready, read fulfillment services, kitting and assembly, pick, pack and ship, or subscription box fulfillment, then request a quote with your monthly volume and where it ships.
Still deciding on the material? The free sample kit ($19.99 shipping, credited to your first order) puts the stock in your hands first. Questions: call (224) 546-8325 or email info@tealpackaging.com.
Configure & order
Pick size, material, and finish, choose a quantity, and check out securely. Every price includes free US shipping.
Proof & approve
Send artwork or a logo. Our US design team preps the dieline free and sends a digital proof, with two revision rounds.
Print & deliver
Once you approve, production runs from about 7 business days, then free US shipping with tracking to your door.
When should I use a mailer box instead of a shipping box?
A mailer box folds from one die-cut piece and locks shut without tape, sized close to the product, so it doubles as the box the customer opens. A shipping box is the better call when you are packing several items together, adding void fill, or sending something heavy or awkwardly shaped.
Which flute or board strength do these mailers use?
If your 3PL, retailer or freight contract needs a named flute or ECT rating documented, request a quote first so the specification is confirmed in writing before you order. Teal's free paper weight chart is a useful reference for how paperboard and corrugated weights compare while you work out what to ask for.
How do I stop an oversized mailer costing me in shipping?
Carriers bill on the greater of actual weight and dimensional weight, so an extra inch of depth can cost more than the board does. Measure the packed product, not the empty box, then run the numbers through Teal's free box size and dimensional weight calculator before you settle on a size.
Should I print the inside of a mailer box?
The inside is what a customer sees at the moment of opening, so it is the panel worth spending on for direct-to-consumer orders. The outside travels through the carrier network, where heavy ink coverage shows scuffs and handling marks more than a lighter design does. Price both before you decide.
What does an online mailer box order include?
Free dieline design, free US shipping, and a digital proof that you approve before anything prints. Pricing runs live at every quantity break, so the per-unit cost at your quantity is visible before you pay, and the minimum that applies is the one on this product's page rather than the 50-unit custom figure.