Custom Mailer Boxes

Custom Mailer Boxes Printed with Your Logo

Custom mailer boxes are self-locking, tuck-front boxes made from corrugated board. They ship on their own, without an outer carton, and open like a gift. That makes them the standard box for subscription boxes, e-commerce orders, PR kits and product launches. John Packaging prints mailer boxes in any size you need, inside and out, and delivers them flat-packed anywhere in the USA.

Why Brands Choose Mailer Boxes

• Ship and present in one box: the corrugated walls protect the product in transit, and the printed lid turns the delivery into an unboxing moment.
• No tape or glue needed: the folding tuck flaps lock the box closed, so packing is fast and the customer opens it cleanly.
• Flat-packed: mailer boxes arrive flat and fold up in seconds, which saves storage space until you need them.
• Room for your brand: print the outside, the inside of the lid, or both, with your logo, colors, patterns and messages.

Materials

Mailer boxes are made from corrugated board, with a choice of facing:

• Kraft: natural brown board for an eco-friendly, rustic look. See custom kraft boxes.
• White: a clean white surface that makes full-color print and brand colors stand out.
• Heavier corrugated grades: for heavier or fragile products. See custom corrugated boxes.

Not sure which board fits your product? Tell us what you are shipping and its weight, and we will recommend the right material with your quote.

Printing and Finishes

We print mailer boxes with digital printing for short runs and detailed artwork, and with offset or flexographic printing for larger runs. We match brand colors with Pantone (PMS) color matching. Finish options include:

• Matte or gloss coating, including aqueous coating and UV coating.
• Spot UV to make a logo shine against a matte background.
• Varnish for extra scuff protection in the mail.
• Inside printing, custom inserts and dividers to hold products in place.

Who Uses Custom Mailer Boxes

• Subscription boxes: a monthly box your customers recognize on the doorstep.
• E-commerce and DTC brands: apparel, accessories and lifestyle products. See custom apparel boxes.
• Beauty and skincare: gift sets and PR kits. See custom cosmetic boxes.
• Food and treats: cookies, chocolates and snack boxes shipped to customers. See custom food boxes.
• Corporate gifting: branded welcome kits and event giveaways. See custom gift boxes.

How to Order

1. Send your details: box size, quantity, material and artwork (or just your logo).
2. Get a quote: we reply with pricing and options.
3. Approve the proof: we send a digital proof before anything is printed.
4. Production and delivery: your boxes are printed and shipped, with free delivery in the USA.

Custom Mailer Boxes FAQs

What is the difference between a mailer box and a shipping box?

A mailer box is a one-piece, self-locking box with a hinged lid, designed to look good when opened. A regular shipping box is a flap-top carton sealed with tape, built mainly for protection and bulk shipping.

Can mailer boxes be shipped without an outer box?

Yes. Mailer boxes are made from corrugated board, so they are designed to travel through the mail on their own.

Can you print on the inside of the box?

Yes. Inside printing is a popular option for a thank-you message, social handles or a pattern that customers see when they open the lid.

Do you make mailer boxes in custom sizes?

Yes. Every mailer box is made to the size you need. Send us your product dimensions and we will size the box to fit.

Are kraft mailer boxes eco-friendly?

Kraft corrugated board is made from paper fibers and is widely recyclable. Ask us about recycled-content and eco-friendly options with your quote.

Browse all box styles, or send your size and quantity through our quote form for pricing on your custom mailer boxes.