Custom Mailer Envelopes

Designed To Deliver Confidence

We help you create mailer envelopes that look professional and stay secure — with strong sealing, sharp printing, and materials built to last through transit.

Material Options

Choose what fits your shipment type best:

• Paperboard – Lightweight and cost-effective
• Kraft – Durable and eco-friendly
• Poly mailers – Water-resistant and tear-proof
• Bubble-lined – Extra protection for delicate items
• Tyvek – Ultra-tough, weatherproof, and lightweight

Custom Sizes Available

From small documents to larger merchandise, we offer custom sizing that fits your specific products without unnecessary bulk or gaps.

Sharp, Branded Printing

We use high-quality printing techniques like digital, offset, and CMYK to print logos, return info, or full-color branding with crisp, lasting clarity.

Add-ons That Secure & Impress

Improve usability and impact with features like:

• Peel & seal closures
• Tamper-evident strips
• Custom windows
• QR codes or barcodes
• Writable surfaces for labeling

Mailer Envelope Types

We supply a variety of envelope styles, including:

• Flat mailers
• Padded or bubble mailers
• Expansion mailers
• Poly mailers
• Full-color printed promotional envelopes

We Focus on the 3Ps

Each mailer envelope is designed with:

• Presentation – Clean layout and professional branding
• Preservation – Keeps items dry, safe, and intact
• Protection – Reinforced seams, secure seals, and tear-resistant materials

Premium Finish Options

Make your envelopes stand out and perform better with:

• Matte or gloss lamination
• Soft-touch coatings
• Foil stamping
• Embossing or debossing
• Spot UV for logo or design highlight

Why Choose Us?

We specialize in making mailer envelopes that reflect your brand and protect your contents from door to door. Trusted by businesses of all sizes, we offer:

• Design help at no extra cost
• Flexible minimum order quantities
• Fast turnaround times
• Strong, eco-conscious materials
• Nationwide shipping options
• Reliable quality control

Get A Quote

Need secure, stylish, and custom mailer envelopes?
To get cost-effective packaging boxes without compromising on quality, you can contact us at (469) 649-8706 or email us sales@customboxeslab.com

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.