Mailer Boxes

About Mailer Boxes

Mailer boxes are the standard for shipping products direct to customers: a one-piece corrugated design that folds into a rigid box with self-locking wings — no tape, no void of structural strength. The fluted wall protects contents in transit while the flat profile keeps freight and storage costs down. They suit apparel, books, cosmetics, food, and electronics alike. Made in Cheshire, Connecticut, our mailers start at 100 units with no setup or die charges, ship flat, and qualify for free shipping anywhere in the contiguous US.

Why US brands choose us for mailer boxes

Custom Box Printing manufactures mailer boxes from our US production facility, with free standard shipping anywhere in the contiguous United States and a 7–10 business day turnaround. We've printed mailer boxes for solo founders launching their first product line, growing direct-to-consumer brands placing 5,000-unit runs, and established retail brands with 50,000+ unit production schedules — and we treat all three the same: no minimums, free design support, no setup or die-plate charges, and a 3D digital mockup before anything goes to press.

Every mailer boxes order includes free in-house dieline and artwork support — our US-based designers will polish your existing files, or build a custom dieline from scratch to fit your exact product dimensions. We send you a 3D mockup to confirm look and proportions before production. For color-critical work, request a physical sample for $50 — the full $50 is credited back to your production order the moment you proceed, so it's never a sunk cost.

Materials, print, and finish options

Standard build is E-flute corrugated (about 1.5 mm) — strong enough for most parcels yet thin enough to fold cleanly and print sharply. For heavier or breakable items, B-flute adds crush strength. Kraft liner gives a recyclable, no-frills look; white liner is ready for full-color print. The double-wall side panels created by the folding design add stacking strength in transit and on the shelf.

Available finishes include:

• Lamination: Gloss, matte, soft-touch, or velvet finish for a premium hand-feel.
• Foil stamping: Gold, silver, copper, or custom foil colors for high-visibility brand marks.
• Embossing & debossing: Tactile raised or recessed surface effects on logo or key artwork.
• Spot UV: Selective gloss coating that creates contrast against matte areas.
• Eco-friendly options: Recycled kraft, FSC-certified stocks, water-based inks, recyclable rigid constructions.
• Compliance: FDA food-safe inks; certified child-resistant constructions for CBD/cannabis where required.

If you're not sure which combination will work best for your mailer boxes, mention it in your quote request — our team will recommend the right material, print spec, and finish based on your product, budget, and brand positioning.

How to order your mailer boxes

1. Request a quote — use the "Get Free Quote" button on this page, or call (855) 792-3890 (toll free). Tell us your box style, dimensions, quantity, material preferences, and any deadline.
2. We respond within 1 business day with pricing, lead times, and material recommendations. No pressure, no commitment.
3. Free design + 3D mockup — we build your dieline (or polish your existing artwork) and send you a 3D digital mockup to approve.
4. Optional physical sample — order a $50 sample to hold the box in hand. The full $50 is credited to your production order.
5. Production & free US shipping — once you approve, we print and ship in 7–10 business days, free anywhere in the United States.