Custom Bux Board Mailer Box

Designed to Fit Your Brand Vision

Your mailer box should reflect your brand’s values from the moment it arrives. Customize the structure, size, and design to match your aesthetic and product needs.

Preferred For

• E-Commerce Orders
• Subscription Boxes
• Retail Product Packaging
• Corporate Gift Mailers
• Event Merchandise Boxes

Materials

• Bux Board – Lightweight yet sturdy for light to medium items
• Kraft Bux Board – Eco-friendly with a natural look
• Coated Paperboard – Smooth surface for vibrant printing
• Reinforced Bux Board – For added durability during transit

Sizes

Available in multiple sizes—from slim envelopes to deeper mailers—designed to fit apparel, cosmetics, books, and more.

Printing

Create a lasting impression with:

• Digital printing
• Offset printing
• Pantone color matching
• Logo and messaging on inside and outside

Add-ons

Enhance the unboxing experience with:

• Self-locking tabs
• Tear strips for easy opening
• Printed inner panels
• Custom inserts or tissue wraps

Types of Mailer Boxes

• Roll-End Tuck Top Boxes
• Front Lock Mailer Boxes
• Tabbed Mailer Boxes
• Flat-Mailer Envelopes
• Self-Sealing Mailers

3Ps of Packaging Approach: Presentation, Preservation & Protection

Presentation

Clean lines and branded visuals create a memorable unboxing experience.

Preservation

Protects against dust, scratches, and minor handling damage.

Protection

Keeps contents secure and stable during shipping and delivery.

Upgrade to Premium Packaging

Add soft-touch finishes, inside printing, or foil accents to enhance both protection and presentation.

Why Choose Custom Boxes Lab?

We deliver mailer boxes that balance form, function, and branding.

• Custom sizes and structural options
• Eco-conscious materials available
• Bulk ordering and fast turnaround
• Design assistance from start to finish

Get a Quote Today

Deliver your products with confidence and style.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.