Custom Mailer Boxes

Custom mailer boxes are one-piece corrugated shipping cartons that fold flat and self-lock without tape, giving e-commerce brands a durable box and a branded unboxing moment in one. Packaging Vista prints mailers inside and out on E-flute or B-flute corrugated in full CMYK and Pantone-matched color, with finishes including matte and gloss lamination, soft-touch, foil stamping, and spot UV. With a 100-box minimum, free design, dieline, and 3D mockup, and no die, plate, or setup fees, your branded mailers ship within 8 to 10 business days with free US delivery.

Mailer box styles

The structure sets the closure, the strength, and the unboxing feel. These are the custom mailer box styles we make most often:

Roll end tuck top (RETT) mailer boxes

The classic mailer: the side walls roll over to create double-thick edges, and a top lid flap tucks into the front to lock the box without glue or tape. RETT mailers ship flat, pop up in seconds, and are the default for branded e-commerce shipping.

Roll end front tuck (REFT) mailer boxes

A close cousin of the RETT where front flaps lock into the body for an even more secure closure, with dust flaps that keep dirt out. REFT mailers are a strong fit for heavier or more fragile products that need extra hold in transit.

Mailer boxes with tear strip

A perforated tear strip plus an adhesive seal lets customers open the box cleanly and, on peel-and-seal versions, reseal it for returns. Tear-strip mailers suit subscription and direct-to-consumer brands that want a tamper-evident, frustration-free open.

Full-flap and literature mailer boxes

Full-flap (literature) mailers are flat, book-style boxes built for shipping printed materials, apparel, and slim products, often with a tear strip or inserts to keep contents centered and scuff-free.

Corrugated and double-wall mailer boxes

For heavier or fragile goods, a B-flute or double-wall corrugated mailer adds crush resistance and stacking strength while keeping a smooth, printable exterior.

Mailer box materials

Most mailers are printed on corrugated stock chosen for your product weight:

• E-flute corrugated - thin and smooth, the best printable surface for crisp full-color graphics on lighter products.
• B-flute corrugated - thicker, with more crush resistance for heavier items or boxes that ship on their own.
• White vs. kraft - white liner for bright, photographic print; natural kraft for an organic, recyclable look. See our kraft boxes for the unbleached option.

Custom mailer boxes with your logo

We print mailers to your exact artwork in full CMYK and Pantone-matched color, inside and out, with a free custom dieline and 3D mockup so you approve the print and fit before production. Inside printing is a popular way to add a brand message or pattern that greets the customer at the open. No die, plate, or setup fees - your branding, your dimensions, from the first 100 boxes.

Mailer boxes by use

Mailers fit almost any product that ships direct to the customer:

Pricing, minimums, and turnaround

Mailer box price depends on the box size, flute and material, print coverage (one side vs. inside and out), finishes, and quantity (our complete mailer box guide for e-commerce walks through each choice) - and the per-box cost drops as volume rises. There are no die, plate, or setup fees, the minimum is 100 boxes, and standard production runs 8 to 10 business days after proof approval, with rush available. Every order includes a free dieline, 3D mockup, and free US shipping. Weighing domestic vs. overseas? See why brands choose a US mailer box manufacturer. Request a free quote with your size and quantity for exact pricing.

Frequently Asked Questions

What style of mailer box do you make, and is it sturdy enough for shipping?

We make roll end tuck top (RETT) and roll end front tuck (REFT) mailers, where the side walls fold over into double-thick edges and a front flap tucks in to lock the box without tape. That self-locking corrugated structure holds up well in transit and protects products through the mail stream.

Can you print on the inside of the mailer box, not just the outside?

Yes. Inside printing is one of the most popular mailer options for a branded unboxing, so we can run full-color artwork or a brand message on the interior panels. We will show both the exterior and interior in your free 3D mockup before printing.

What material and flute do you recommend for e-commerce mailers?

Most e-commerce mailers are printed on E-flute or B-flute corrugated. E-flute is thin and smooth for crisp graphics on lighter products, while B-flute and double-wall add crush resistance for heavier or fragile items. We will recommend a flute based on your product weight and whether the box ships on its own.

Can I add a tear strip or peel-and-seal closure?

Yes. We can add a perforated tear strip for easy, clean opening and a peel-and-seal adhesive strip so customers can reseal the box for returns. Both are popular on subscription and direct-to-consumer mailers and are built into your dieline before production.

How much do custom mailer boxes cost?

Cost depends on the box size, flute and material, how much you print (outside only versus inside and out), finishes, and order quantity, and it falls as volume increases. Because every job is custom, we quote per project rather than list a flat price, but there are never die, plate, or setup fees, and the minimum is just 100 boxes. Send your dimensions and quantity for an exact, no-obligation quote.

What sizes and dimensions can I get for a mailer box?

Any size - mailers are made to your product dimensions, given as length x width x depth. If you are unsure, send a sample or product specs and we will size the box and supply a free dieline and 3D mockup to confirm the fit before production.

What is the lead time and minimum order on mailer boxes?

The minimum is 100 mailer boxes with no die, plate, or setup fees, so it is easy to launch a custom size and design. Plan for the standard 8 to 10 business-day turnaround after proof approval, with rush production available if your launch date is tight.