Custom printed mailer boxes and postal boxes
Custom Printed Mailer Boxes
Mailer boxes are die-cut corrugated boxes with a fold-over lid and tuck-in front that close without tape, so one box protects the order in transit and presents it when it is opened. We make custom printed mailer boxes and postal boxes to your internal dimensions, in E flute, B flute or double wall board, printed on the outside, the inside or both. Send your dimensions and quantity for a quotation.
- Construction
- Die-cut corrugated, delivered flat
- Board
- E flute, B flute or double wall
- Outside, inside or both
- Minimum order
- 50 boxes
Overview
A transit box that is also the first impression
A mailer box does two jobs. It has to survive a courier or postal network, and it is usually the first physical contact a customer has with your brand. The outside is seen by everyone who handles the parcel; the inside is seen only by the customer. That is why most branded mailers carry a durable logo design on the outside and save the full-colour artwork or a message for the inside of the lid.
Mailer boxes are die-cut from a single sheet of corrugated board, a fluted layer glued between two flat liners, and fold up without glue or tape. Side walls fold in and lock with tabs, dust flaps close the gaps at the corners, and the front of the lid tucks into the base. The result is a box that closes firmly on its own, opens like a lid and can be reused for returns.
Postal boxes and postage boxes are the same thing when they are printed and cut to size: a corrugated box made to go through the post without an outer carton. The main decisions are the flute, the liner colour, where the print goes and whether an insert is needed to stop the contents moving. We recommend the flute with your quotation once we know what you are sending and roughly what it weighs.
A mailer is not the same as a slotted shipping carton. A slotted carton has four flaps that are taped shut and are cut open on arrival; it suits bulk and trade shipments where nobody sees the box. A mailer is chosen when the customer opens the box and presentation matters.
Structures
Mailer box styles
Roll-end tuck front is the standard mailer construction. The variations below change how the box opens, how thick the walls are and how it is presented.
Box style
Roll-end tuck front mailer boxes
The classic one-piece mailer: rolled side walls, locking tabs, dust flaps and a front lip that tucks into the base.
Read the style guideBox style
Corrugated lid and base boxes
A separate lid over a corrugated tray. Gives a lift-off reveal for subscription and gift mailers.
Read the style guideBox style
Mailers with a printed sleeve
A plain or lightly printed mailer inside a full-colour card sleeve, useful when one box size serves several products.
Read the style guideMailers with a tear strip
A perforated strip that opens the box cleanly and shows whether it has been opened before arrival.
Double-wall side panels
Side panels fold over twice for thicker walls and a clean inside edge with no cut board showing.
Sizing
Choosing the right mailer size
Give us internal dimensions: the length, width and depth of the space the contents need, including any insert or tissue. We add the board thickness to arrive at the external size. A mailer should fit closely, because a box much larger than the contents needs void fill, moves the product about in transit and costs more to send.
Roll-end mailers work best when the depth is smaller than the length and width. For deep or tall products a corrugated lid and base box or a different corrugated style usually performs better, and we will advise. If you already use a stock mailer, tell us its size and what you would change about it.
If you post through Royal Mail or a courier, check the external dimensions and packed weight against the size band you use before you fix the size. A few millimetres can move a parcel into a more expensive band. If you ship several product sizes, two or three mailer sizes often cover the range better than one large box with extra fill.
Materials & finishing
Flutes, liners and board
The flute decides how the box protects and prints; the liner decides the colour of the print surface. Thicknesses are approximate and vary by mill and board grade, so we confirm the board on your quotation.
| Specification | Typical range | Notes |
|---|---|---|
| E flute | About 1.5 mm | Fine flute with a smooth surface that takes detailed print well. The usual mailer board for lighter products, cosmetics and subscription boxes. |
| B flute | About 3 mm | More crush resistance and cushioning. The general-purpose choice for heavier e-commerce orders and boxes that stack in transit. |
| Double wall (such as EB or BC) | About 4–7 mm | Two fluted layers for heavy, bulky or fragile contents and for boxes handled repeatedly through a distribution chain. |
| White liner | Coated or uncoated white top | A clean white surface for accurate full-colour print and pale brand colours. |
| Kraft liner | Natural brown | An unbleached look that suits one- or two-colour designs. Full colour prints darker and warmer on kraft, and white cannot be printed as a colour. |
Finishes
- Matt or gloss lamination on printed liners
- Water-based varnish
- Foil blocking on the lid
- Spot UV
- Inside printing
Options
Options you can specify
Printing
- One or two Pantone colours on kraft
- Full-colour CMYK on a white liner
- Inside print on the same blank
- Flood colour across the whole box
Structure
- Tear strip opening
- Thumb cut-out on the front lip
- Double-wall side panels
- Locking tabs for a firm close
Inserts
- Corrugated platforms and dividers
- Card inserts with cut-outs
- Foam inserts for fragile items
- Printed card inserts carrying a message
Finishing
- Matt lamination for scuff resistance
- Soft-touch lamination on premium mailers
- Foil-blocked logo
- Spot UV on a laminated lid
Applications
What mailer boxes are used for
E-commerce orders
Right-sized mailers that close without tape, carry the brand on the outside and reduce void fill.
Subscription boxes
One standard size set from the largest regular item, with inside print and an insert that presents the month's contents.
PR and influencer send-outs
Full-colour inside and outside print, a fitted insert and a card message, designed to be opened on camera.
Postal boxes for small products
Shallow mailers for accessories, stationery, prints and small gifts sent through the post.
Cosmetics and skincare
E flute mailers with a card insert holding cartons or bottles in fixed positions.
Apparel
Shallow, wide mailers for folded garments, with tissue and a printed inner lid.
Candles and home fragrance
Mailers with corrugated or card inserts that stop glass jars touching each other in transit.
Compare
Printed mailer box or slotted shipping carton?
| Feature | Printed mailer box | Slotted shipping carton |
|---|---|---|
| Closure | Tuck-in front with locking tabs, no tape needed | Four flaps taped shut |
| Opening | Opens like a lid towards the customer | Cut open with a knife |
| Printing | Outside and inside, full colour possible | Usually plain or simple one-colour marks |
| Best for | Direct-to-customer orders where the box is seen | Bulk and trade shipments where it is not |
| Reuse for returns | Straightforward; the box closes again | Needs fresh tape |
How to choose
How to choose your mailer box
Choose the flute for the contents
E flute for lighter products where print quality matters most, B flute as the general-purpose grade, and double wall for heavy or fragile items. Tell us the weight and fragility and we will recommend the board.
Size it close to the product
A close fit protects better and costs less to send than a large box with void fill. Measure the contents in millimetres, including any insert, tissue or printed card.
Put each design where it works
The outside is handled, stacked and scuffed, so keep it bold and durable. The inside is seen only by your customer, which makes it the place for full-colour artwork or a message.
Decide on kraft or white early
Kraft gives a natural look and suits simple designs; white gives true colour. Changing the liner later changes how every colour in the artwork prints.
Plan the unboxing order
Think about what the customer sees first when the lid lifts: a printed inner lid, a message card, tissue, then the product held in position. Each of these can be built into the specification.
In detail
Details that make a better mailer
Inside print the right way up
Artwork on the inner lid must read correctly when the lid is opened towards the customer. We check the orientation on the dieline before the proof is issued.
A front lip that stays shut
The tuck at the front of the lid and the locking tabs keep the box closed through handling without tape. A thumb cut-out makes it easy to open again.
Dust flaps and corners
Dust flaps close the gaps at the corners so small items cannot slip out and dust stays out. They also add stiffness to the side walls.
Delivered flat
Mailers are delivered flat and folded up at packing, so they take little storage space. Delivery is included on every order, and your quotation confirms the delivery address and timing.
Finished work
Mailer Boxes we have made
Roll-end tuck front mailer boxes · Corrugated board
Mailer Boxes questions
Questions buyers ask
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat is the difference between a mailer box and a shipping carton?
A mailer box is die-cut so the lid is part of the box and closes with tuck flaps and locking tabs, without tape. A regular slotted shipping carton has four flaps that are taped shut. Mailers are the choice when the customer opens the box and presentation matters.
Which flute should I choose for my mailer box?
It depends on the weight and fragility of the contents. E flute suits light products and print-led designs, B flute is the general-purpose grade, and double wall is for heavy or fragile items. We recommend the flute once we know what you are sending.
Can you print inside a mailer box?
Yes. Inside print is applied to the same sheet as the outside, so it is an efficient way to brand the opening moment. It can be full colour even when the outside is a simple one- or two-colour design.
Are postal boxes and mailer boxes the same?
In practice, yes. A postal box is a corrugated box designed to go through the post without an outer carton, and the roll-end tuck front mailer is the most common version. The page you are on covers both.
Can mailer boxes go through Royal Mail and couriers without an outer box?
Yes, that is what they are designed for, provided the flute suits the weight and the contents are held in place. Check the external size and packed weight against the size band you use before you fix the dimensions.
What is the minimum order for mailer boxes?
The minimum order is 50 boxes. Unit cost falls as quantity rises because setup is spread across the run, so ask for two or three quantities if you are deciding how many to order.
How long does a mailer box order take?
It depends on the print, finish and quantity. The steps that take time are artwork and proof approval, printing and die-cutting. Tell us your required delivery date and our team will confirm whether the timing is achievable.
Can I print full colour on kraft mailer boxes?
You can, but the brown base shifts the colours: pale shades read warmer and white cannot be printed as a colour. For exact brand colours or photographs, choose a white liner. For a natural look, one or two Pantone colours on kraft usually gives the best result.
Can I see a sample first?
You approve a digital proof showing your artwork on the dieline before production. Ask about sample options when you request your quotation.
Ready to specify your packaging?
Our team replies during business hours, 10:00–18:00 UK time.