Custom Printed Mailer Boxes

Custom Printed Mailer Boxes Designed Around Your Brand

Custom printed mailer boxes have become the standard for e-commerce brands that refuse to ship in plain brown packaging. These tuck-end corrugated mailers lay flat for efficient warehouse storage, pop open into a rigid self-locking box, and protect products during transit without extra padding or tape. Every box is printed and constructed to your exact specifications so your customers receive packaging that reflects the quality of what is inside.

Full Customization From Structure to Finish

Every order starts with your choice of dimensions. Whether you ship cosmetics, subscription kits, apparel, or tech accessories, your mailers are sized to fit snugly and reduce product movement inside the box. Full-color CMYK printing covers the entire exterior and interior surfaces, giving you complete creative control over both sides of the packaging.

Finishing options let you dial in the exact look and feel your brand needs. Matte lamination delivers a smooth, modern texture that feels premium in hand. Gloss lamination adds vibrancy and a slight sheen that makes colors pop. Spot UV highlights specific design elements like your logo or tagline with a raised, glossy accent that catches light. Foil stamping in gold, silver, or custom metallic tones adds a luxury touch. Embossing and debossing create tactile depth that customers notice the moment they pick up the box.

Durable Construction With Eco-Friendly Materials

These mailers are constructed from corrugated cardboard in E-flute or B-flute depending on your product protection requirements. E-flute corrugated is the most popular choice for lightweight products, offering excellent crush resistance at just 1.5mm thickness. B-flute provides heavier cushioning for fragile or heavier items at 3mm thickness. Thick paperboard options from 18pt to 24pt are also available for products that need a more refined, less industrial feel.

All materials are recyclable and sourced from FSC-certified suppliers. Soy-based inks are used across every print run, keeping your packaging aligned with sustainable practices. If your brand promotes eco-conscious values, these mailers back that up with materials your customers can feel good about recycling curbside.

Who Uses Custom Printed Mailer Boxes

• Subscription box companies shipping monthly beauty, snack, or wellness kits
• E-commerce apparel brands replacing plain poly mailers with branded packaging
• Cosmetics and skincare lines that need presentable unboxing for social media
• Specialty food brands shipping chocolates, coffee, or tea samplers
• Small electronics sellers packaging phone cases, cables, or accessories
• Gift box retailers creating curated holiday or occasion sets
• Direct-to-consumer brands where packaging is the first physical brand impression

Custom mailers work especially well for products featured in influencer unboxing content, where packaging quality is visible to thousands of potential customers and directly impacts brand perception.

Available Sizes and Configurations

We offer fully custom sizing to match your exact product dimensions. Common configurations include small mailers (6×4×2 inches) for jewellery and accessories, medium mailers (10×8×4 inches) for cosmetics and subscription kits, and large mailers (16×12×6 inches) for clothing and multi-product shipments. Non-standard sizes are manufactured at no additional cost.

Structural options include standard tuck-end, roll-end tuck-top (RETT), crash-lock bottom for faster packing, and ear-lock designs for maximum security. Each configuration is selected based on your product weight, packing speed requirements, and unboxing experience goals.

Why Brands Choose The Treasure Boxes

There are no minimum order requirements — start with as few as 50 units to test your design before committing to a larger production run. Every order ships free within the United States. Standard turnaround is 7-14 business days from artwork approval, with rush options available for time-sensitive launches.

Our design team provides free support including custom dieline templates, 3D mockup renders, and two rounds of artwork revisions. We handle the entire process from structural design through printing and shipping so you can focus on your products while we handle the packaging.

How to Order Custom Mailer Boxes

1. Submit a quote request with your dimensions, quantity, and design references
2. Receive detailed pricing within 4 business hours
3. Send your artwork or work with our free design team
4. Approve the digital proof and production begins
5. Boxes ship free in 7-14 business days