Custom Mailer Boxes

Why 5,000+ Brands Choose BoxesGen for Their Mailer Boxes

We make custom packaging simple, fast, and affordable — without cutting corners on quality. Here is what you get with every order:

• $0.10 Sample Box — try before you commit to a full run
• Free Shipping across the entire United States
• 5-7 Business Day Production — one of the fastest turnarounds in the industry
• Free Design Support — our team builds your artwork at no extra cost
• 100-Unit Minimum — no massive bulk requirements to get started
• Transparent Pricing — what you see is what you pay, no hidden fees
• FSC & SFI Certified Materials — eco-responsible from day one
• Premium Print Quality — full CMYK, Pantone, offset, and digital options

5,000+ brands — from Shopify startups to established retail names — trust BoxesGen for consistent quality, honest pricing, and packaging that arrives on time.

What Are Mailer Boxes — And Why Do Ecommerce Brands Love Them?

Mailer boxes (also called roll-end tuck top boxes or RETT boxes) are rigid, self-locking shipping containers made from corrugated cardboard. Unlike plain brown shipping boxes, mailer boxes are designed to look great when opened — making them the go-to packaging for ecommerce brands, subscription box businesses, and premium retail products.

They fold flat for storage and easy assembly, lock closed without tape, and offer a rigid structure that protects products during transit without the bulk of a traditional carton. Their interior face is fully printable, which means your branding is the first thing customers see when they open the box.

Common uses include subscription boxes, cosmetics packaging, apparel mailers, electronics shipping, and corporate gift kits. If your customer’s unboxing moment matters to your brand, mailer boxes are the right choice.

Choose the Right Mailer Box Style for Your Product

Every product ships differently. We offer the following mailer box configurations to match your needs:

• Roll-End Tuck Top (RETT) — the most popular style; secure side tucks, no tape needed, opens cleanly
• Tab-Locking Mailer Box — extra-secure closure ideal for heavier or fragile items
• Literature Mailer Box — shallow profile designed for books, magazines, flat documents, and print media
• Regular Slotted Container (RSC) — cost-effective style for high-volume ecommerce and B2B shipping
• Five-Panel Fold Box — used for long, narrow, or unusually shaped items
• One-Panel Fold Box — lightweight option for very flat items like greeting cards or stationery

Not sure which style fits your product? Request a free sample or speak with our packaging team — we will recommend the most cost-effective structure for your weight, dimensions, and budget.

Built-In Features That Protect Your Product and Elevate Your Brand

Every BoxesGen mailer box is engineered for real-world shipping conditions. Standard features include:

• Self-locking design — assembles in seconds, no tape or glue required
• Triple-layer corrugated construction — resists crushing, compression, and edge impact
• Custom foam, cardboard, or molded inserts — holds products securely in position
• Hinged lid option — creates a premium open-and-reveal unboxing experience
• Full interior and exterior printing — brand every surface of the box
• Stackable structure — optimized for warehouse storage and bulk fulfillment

These are not commodity shipping boxes. BoxesGen mailer boxes are structural packaging tools that protect your product and sell your brand simultaneously.

Unlimited Customization — Make Every Box Uniquely Yours

Your mailer box is a blank canvas. Here is everything you can tailor to your brand and product:

Size & Structure

We produce mailer boxes in any dimension. The industry-standard size is 9.5″ x 7.75″ x 4″ (interior), but we custom-cut every order to your exact product measurements to minimize void fill and reduce shipping weight.

Materials

Choose from:

• E-flute corrugated cardboard — lightweight, smooth print surface, ideal for ecommerce brands
• B-flute corrugated cardboard — stronger, better for heavier or fragile products
• Kraft corrugated — natural brown finish for an eco, handcrafted brand aesthetic
• White corrugated — bright base for vivid color printing and photographic artwork
• Rigid paperboard — premium feel for luxury goods, cosmetics, and gifting

Printing

We offer the full range of print methods to match your quality and budget requirements:

• CMYK full-color digital printing — ideal for photographic or gradient-heavy artwork
• Offset lithographic printing — highest color fidelity for large runs
• Flexographic printing — cost-effective for single or two-color brand marks
• Screen printing — bold, solid colors with excellent coverage
• Pantone-matched printing — exact brand color replication

All inks are available in water-based or soy-based formulations for eco-compliant packaging.

Finishes

Upgrade your surface with:

• Matte or gloss lamination — protection and premium feel
• Soft-touch matte coating — velvety texture that stands out on shelf and in hand
• Aqueous coating — fast-dry, scuff-resistant clear coat
• Spot or flood UV gloss — high-shine highlights on logos or key visuals
• Gold or silver foil stamping — metallic accents for luxury packaging
• Embossing or debossing — raised or recessed brand marks and logos

Add-Ons

Enhance the unboxing moment with:

• Tissue paper, ribbon pulls, and bow tie closures
• Magnetic closure upgrades
• Tear strips for easy opening
• QR code panels and NFC integration
• Personalized inserts and thank-you cards

Standard Mailer Box Sizes — and What Fits Inside

Use this guide to find the right starting size for your products. All sizes are fully customizable.

Not finding your size? All dimensions are fully customizable. Share your product measurements and we will engineer the perfect fit.

Industries That Rely on Custom Mailer Boxes

Mailer boxes are the preferred packaging format across a wide range of industries. We serve:

• Ecommerce & DTC Brands — durable, branded shipping that reduces returns and boosts reviews
• Subscription Box Businesses — monthly box packaging that customers look forward to opening
• Cosmetics & Skincare — premium presentation that matches the quality of your formulas
• Apparel & Fashion — flat-pack mailers that protect garments and reflect your brand identity
• Food & Beverage (non-perishable) — moisture-resistant corrugated for specialty food brands
• Electronics & Tech Accessories — protective inserts and secure closures for fragile items
• Books, Stationery & Media — literature mailer boxes sized for flat media
• Corporate Gifting & PR Kits — high-impact unboxing for influencer sends and employee gifts
• Pharmaceutical & Health Products — tamper-evident closures and clinical-grade materials
• CBD & Wellness Brands — compliant, discreet, or fully branded mailer options

Whatever your product, our packaging consultants will help you design a mailer box that ships safely, arrives beautifully, and reinforces your brand from the moment it is in your customer’s hands.

Built to Survive Real Shipping Conditions — Not Just Look Good in Photos

BoxesGen mailer boxes are manufactured from high-grade corrugated cardboard with a standard three-layer fluted construction. The inner flute acts as a shock absorber, distributing pressure evenly across the box walls so your product arrives undamaged even after multiple handling points in transit.

All materials are tested to withstand:

• Edge crush test (ECT) rated for standard UPS/FedEx/USPS handling loads
• Moisture exposure from temperature fluctuations during shipping
• Stacking pressure in warehouse and delivery vehicle environments
• Drop and impact forces during automated sorting

For products that require extra protection — glass, ceramics, electronics, or cosmetics — we offer custom-cut inserts in foam, corrugated honeycomb, molded pulp, or cardboard configurations. Inserts are produced to the same tolerances as your box, ensuring a snug fit with zero product movement.

Eco-Friendly Mailer Boxes — Sustainable Packaging That Performs

More than 70% of consumers say sustainable packaging influences their purchase decision. BoxesGen makes it easy to ship responsibly without sacrificing print quality or structural performance.

Our eco-friendly mailer box credentials include:

• 99% recyclable corrugated cardboard construction
• FSC-certified (Forest Stewardship Council) paper sources
• SFI-certified (Sustainable Forestry Initiative) supply chain
• Soy-based and water-based inks — no VOC emissions, safe for food-adjacent packaging
• Right-size custom dimensions — reduce material waste and void fill by 30-40%
• Plastic-free construction available on all standard mailer box styles
• Post-consumer recycled (PCR) kraft options

Every BoxesGen mailer box arrives fully flat-packed, reducing shipping volume and carbon emissions from logistics. We also offer carbon offset programs for high-volume customers.

Switching to sustainable custom mailer boxes is not just good for the planet — it is a competitive advantage your customers will notice.

How Your Custom Mailer Boxes Go From Concept to Your Door

We have refined our process over thousands of orders to make it as smooth and transparent as possible:

• Consultation: Share your product dimensions, quantity, and design goals. We recommend the optimal material, structure, and finish for your use case.
• Structural Design: Our engineers create a structural dieline and 3D mockup for your approval.
• Artwork Review: Upload your artwork or work with our designers. We provide a print-ready proof for sign-off.
• Sample Approval: We produce a physical sample ($0.10) for you to hold, test, and approve before full production begins.
• Production: Once approved, your order enters production. We manufacture to the same specification as the approved sample — every time.
•  Quality Inspection: Every order goes through a multi-point inspection covering print registration, structural integrity, and dimensional accuracy.
• Delivery: Your boxes ship free to any US address, arriving flat-packed and ready to use.

Custom Mailer Box Pricing — Wholesale Rates by Quantity

Our pricing scales with your order volume. The more you order, the lower your per-unit cost. Below are estimated starting price ranges — your exact quote depends on size, material, and finish selections.

Prices shown are estimates for standard single-color or two-color printing on E-flute corrugated. Full-color print, premium finishes, and custom inserts may adjust pricing. All quotes include free shipping to US addresses.

Ready to Build Your Custom Mailer Boxes?

Join 5,000+ brands that trust BoxesGen for premium custom packaging that ships on time, every time. Get a free, no-obligation quote in minutes — our team typically responds within 2 business hours.

• Free design support included with every order
• $0.10 sample before you commit to full production
• Free shipping across the continental United States

302-778-9458 or write us an email at sales@boxesgen.com to get started on your wholesale custom packaging order, whether it is for apparel boxes or retail packaging.