Mailer Boxes: The Complete Guide for E-Commerce

A mailer box is a self-locking corrugated box that folds together without tape, with protective wings that secure the contents. It is the default for e-commerce because it ships flat, assembles in seconds, survives the mail, and prints beautifully inside and out. This article goes deeper on mailers than our box styles overview.

How a mailer box is built

Most mailers use a roll-end tuck design: a one-piece corrugated blank that folds into a sturdy box with side wings and a front tuck flap. There is no glue or tape at the customer’s end – it locks closed. The corrugated board gives it strength and a little cushioning for transit.

When to use a mailer box

Mailers suit apparel, beauty, subscription boxes, and most light-to-medium products that ship direct to consumers. For very heavy or fragile goods, a heavier corrugated box may be better. See mailer boxes for options.

Design it for the unboxing

The inside of a mailer is prime branding space – a printed interior turns the open into a moment. Add a fitted insert to hold the product and a thank-you card to finish it. Our inserts and unboxing guide covers this.

Right-size to save

Mailers ship flat and price by size, so a box built to the product cuts cost and waste. See how to measure and our e-commerce packaging guide.

Get custom mailer boxes

Tell us your product and size, and we will build a mailer with a free dieline – no die or plate fees, from a 100-box minimum. See the full box styles guide, then request your free quote or contact our team.