Black Mailer Box

Minimalist Aesthetic. Maximum Impact.

Our black mailer boxes are perfect for unboxing experiences, curated product kits, PR packages, and influencer send-outs.

Durable Materials for Confident Shipping

We build every black mailer to withstand the rigors of delivery—without sacrificing style.

• Corrugated cardboard (E-flute or B-flute) – Lightweight yet strong
• Rigid mailer board – Ideal for high-end subscription kits
• Matte or gloss lamination – Adds elegance and scratch resistance
• Eco-friendly black kraft options – For sustainable packaging goals

Tailored Sizing and Structural Options

Every product deserves a perfect fit. We offer fully customizable sizes and styles:

• Standard tuck-top mailers
• Front-lock mailers with dust flaps
• Self-seal or adhesive strip options
• Two-piece rigid black mailer sets

Sophisticated Branding Elements

Black is the ultimate canvas. We help you add bold, luxury-grade detailing that makes your brand shine.

• White ink printing on black surfaces
• Spot UV, soft-touch lamination, or velvet finish
• Hot foil stamping in gold, silver, rose gold, or black-on-black
• Interior print for messaging, inserts, or unboxing guides

Add-Ons That Elevate Every Shipment

Want to turn heads the moment your box arrives? Let’s add the extras that deliver wow.

• Custom tissue paper, crinkle fill, or tray inserts
• Thank-you notes or loyalty coupons
• Magnetic closures or pull tabs
• QR codes for product registration or brand videos

The 3Ps of Black Mailer Box Packaging

Presentation

Bold on the outside, thoughtful on the inside. That’s the power of black packaging.

Preservation

Moisture-resistant coatings, strong walls, and secure closure keep contents intact.

Protection

Shock-absorbing flutes and custom inserts ensure safe shipping from warehouse to doorstep.

Why Leading DTC Brands Trust Custom Boxes Lab

We’re the go-to for brands needing packaging that’s tough, beautiful, and brand-right.

• Low minimums and bulk discounts
• Full structural & design support
• Fast U.S. production turnaround
• Eco-friendly black material options
• 1:1 service from packaging experts

Start Your Custom Black Mailer Box Project Today

Let’s build packaging that speaks volumes before it’s even opened. Call 0000 or email Custom Boxes Lab to get your free quote on black mailer boxes made with precision and purpose.

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.