Custom Mailer Boxes
Custom Shipping Boxes
Custom Cardboard Boxes
Custom Kraft Boxes
Custom Product Boxes
Custom Retail Boxes
Custom Tuck End Boxes
Custom Pillow Boxes
Custom Window Boxes
Custom Rigid Boxes
Custom Gift Boxes
Custom Magnetic Boxes
Custom Sleeve Boxes
Custom Printed Boxes
Custom Boxes with Logo
Custom Box Inserts
Custom Mailer Boxes
Self-locking mailer boxes in E flute or B flute corrugated, made to the internal size you give us and printed from 1 colour to full colour on the outside, the inside or both. They post without tape and open like a lid.
- Design proofFree, approved by you before printing
- PriceCustom quote by email within one working day
- Production4–7 working days after proof approval
- DeliveryFree and tracked, UK mainland, 2–3 working days
- Misprints or damageReported within 10 days, reprinted or refunded
Mailer Boxes Made Around Your Product
A mailer box is a single piece of corrugated board with a hinged lid, dust flaps and two locking tabs at the front. It folds into shape without glue or tape, which makes packing quick, and the double-thickness side walls stop it crushing when it sits under other parcels. Most online shops start here because one box does the job of a shipping carton and a presentation box at once.
We cut each mailer to the internal length, width and depth you send in mm. That means the product sits snugly with no void fill, and the parcel stays small enough to keep your courier costs down. Print can go on the outside, the inside or both, so a plain kraft exterior can open to a bright full-colour message the moment the lid lifts.
Where Mailer Boxes Work Best
- Clothing, accessories and folded knitwear sent out from an online shop
- Subscription kits and monthly boxes that customers open on camera
- Press packs, product samples and launch mailings
- Candles, skincare and small gift sets that need to survive the post
Choosing E Flute or B Flute
E flute is the slimmer board at around 1.5 mm. It takes print well, folds crisply and suits most items under a couple of kilos. B flute is closer to 3 mm and adds crush strength for heavier or awkward products. If you are unsure, send us the product weight and we will say which one we would use. For goods that need a lift-off lid instead, look at our custom rigid boxes.
Packing a Mailer Box Step by Step
Mailers arrive flat with the creases already in the board, so there is no scoring or gluing on your side. Once a packer has folded a few, the routine on the bench looks like this:
- Fold the base up and tuck the two side walls in, so the double-thickness walls stand upright.
- Fold the dust flaps inwards and lay in any tissue, insert or paper fill.
- Place the product, then any card or leaflet on top so it is the first thing seen.
- Close the lid and push the two front tabs into the slots in the base until they sit flush.
- Put the address label on the lid, clear of any print you want the customer to notice first.
If several products share one mailer, a card or corrugated insert cut to fit stops them knocking together and makes the box quicker to pack, because each item has its own place.
Where the Print Goes
Where the print sits changes how a mailer feels to receive more than the number of colours does. A quick comparison of the usual options:
| Print layout | What the customer sees | Often chosen for |
|---|---|---|
| Outside only | A branded box on the doorstep, plain inside | Shops whose mailers are reused for returns |
| Inside only | A plain brown box that opens on full colour | Discreet deliveries and gift orders |
| Inside and outside | Brand in transit and again on opening | Subscription kits and launch mailings |
| One colour logo on kraft | A clean, natural look with low set-up cost | Short first runs and simple brands |
Lamination, soft touch and foil can sit over any of these. The guide to print and finish options compared shows how each one looks on corrugated board.
Reorders and Returns
Once a mailer size and design are approved, they are kept on file. A repeat run of the same box goes straight to production after you confirm the quantity, and only a change of size or artwork needs a new proof. Many shops settle on two or three mailer sizes that cover their whole range and reorder them as stock runs down.
If customers often send items back, ask about a tear strip with a second adhesive strip, so the box opens cleanly and can be sealed again for the return. We confirm on the custom quote whether it suits your size and board. For heavy or bulky orders that outgrow a mailer, B flute and double wall shipping cartons take over.
Kraft or white?
Kraft gives a natural brown look and suits 1 or 2 colour print. White makes full colour brighter. We can quote both in one go.
Popular Mailer Boxes Sizes
Internal sizes in mm. Every mailer is cut to order, so any size between these rows is fine.
| Length × Width × Depth | Often used for | Board |
|---|---|---|
| 150 × 100 × 50 mm | Jewellery, cosmetics, small accessories | E flute |
| 220 × 160 × 80 mm | Candles, skincare sets, socks | E flute |
| 250 × 200 × 100 mm | Folded T-shirts, books, gift sets | E flute |
| 300 × 220 × 100 mm | Knitwear, subscription kits | E or B flute |
| 350 × 250 × 120 mm | Shoes, larger kits, hampers | B flute |
| 400 × 300 × 150 mm | Bulky or heavier orders | B flute |
Measure the product, not an old box. Give us the inside size and we allow for the thickness of the board.
Board
E flute for most mailers and B flute for heavier products. Both come with a white or a kraft outer liner, and the inside liner can be white even when the outside is kraft.
From 1 colour up to full colour, outside, inside or both. A popular split is a single-colour logo on kraft outside and full colour inside, which keeps the box discreet in transit and lively on opening.
Finish
Matt or gloss lamination protects the print from scuffs in the post. Soft touch, spot UV, foil and embossing are available when the mailer doubles as a gift box.
Full colour print on white E flute, with matt lamination.
Production and Delivery
Production takes 4–7 working days after you approve the free design proof. Plain kraft mailers with simple print usually sit at the shorter end of that window. Delivery to the UK mainland is free and tracked, and arrives in 2–3 working days once the boxes leave production. The tracking link comes to you by email.
Reprints and Refunds
Check the boxes when they arrive. If any are misprinted or damaged, report it within 10 days with a photo and we reprint or refund the boxes affected. Read the full returns and reprints policy.
Mailers are delivered flat, packed in cartons, with a tracking link by email.
Mailer Boxes Specification
| Style | One-piece mailer with hinged lid, dust flaps and locking front tabs; no glue or tape needed |
|---|---|
| Size | Made to your internal length, width and depth in mm |
| Board | Corrugated E flute or B flute; white or kraft liner |
| 1 colour to full colour; outside, inside or both | |
| Finish | Matt or gloss lamination, soft touch, spot UV, foil, embossing |
| Inserts | Card, corrugated or foam, cut to your product |
| Minimum order | Low, quoted per job |
| Price | From £0.25 a box; custom quote by email within one working day |
| Proof | Free design proof before printing |
| Production | 4–7 working days after proof approval |
| Delivery | Free tracked UK mainland delivery, 2–3 working days |
Design Your Mailer Box
Choose the box photo closest to your mailer boxes, add your logo, drag it into place and set the size. Send it with your sizes and we reply with a custom quote and a free design proof.
Drag the logo, or select it and use the arrow keys (Shift moves faster, + and − resize).
Related Boxes
Other boxes that post well or pair with a mailer.
Custom Shipping Boxes
B flute and double wall cartons for heavier orders and courier handling.
Custom Printed Boxes
Any style printed from 1 colour to full colour, outside, inside or both.
Custom Boxes with Logo
Your logo printed on any box style, one panel or all over.
Custom Box Inserts
Card, corrugated or foam inserts cut to hold each item in place.
Mailer Boxes Questions
What customers ask before ordering mailer boxes.
Do mailer boxes need tape?
No. The front tabs lock into slots in the base, so the box holds shut on its own. Some shops add a sticker or a strip of tape as a tamper seal, but the box does not need it to stay closed.
Can I post a mailer box without an outer carton?
Yes. That is what they are designed for. The folded side walls give two layers of board around the product, which is enough for standard parcel services when the size and board suit the weight.
How much weight can a mailer box take?
It depends on the size and the board. E flute suits light items such as clothing and cosmetics; B flute is the better choice once the contents get heavier. Send the weight and we will recommend a board.
Can you print the inside of a mailer box?
Yes. Inside print is one of the main reasons people choose mailers. You can print the inside only, the outside only, or both, from 1 colour up to full colour.
Will the mailers arrive flat?
Yes. Mailers are delivered flat to save space and fold up by hand in a few seconds. We can send folding guidance with the proof if you have not packed one before.
What size should I ask for?
Give us the internal length, width and depth in mm. Measure the product with any tissue or insert and add a few mm each way so it slides in without forcing.
Can I add an insert to a mailer box?
Yes. Card, corrugated and foam inserts can be cut to hold each item in place. See our custom box inserts for the options.
Is there a minimum order for mailer boxes?
Minimums are low and set per job rather than fixed. Tell us the quantity you need and the custom quote will show the price for that run.
How long do mailer boxes take?
Production takes 4–7 working days after you approve the free design proof, then delivery to the UK mainland takes 2–3 working days.
What if some mailers arrive damaged in transit?
Report it within 10 days of delivery with a photo and we reprint or refund the boxes affected.