Custom Chipboard Mailer Boxes

Designed for Compact Shipping and Branding

Our chipboard mailers are sleek and strong, designed to fold flat for storage and assemble quickly when needed. They’re a smart choice for lightweight items that still deserve premium protection and style.

Materials

Built with precision and purpose:

• Solid chipboard – Dense and sturdy for compact items
• Recycled chipboard – Sustainable and cost-effective
• Clay-coated chipboard – Smooth surface ideal for high-end printing
• Laminated chipboard – Adds extra durability for longer transit

Sizes

Tailored to fit your exact products:

• Small mailers – For cosmetics, jewelry, and electronics
• Medium formats – Ideal for apparel, books, and gifts
• Large flat mailers – Suited for documents, art prints, or kits
• Custom dimensions – Built to your product’s shape and weight

Printing

Promote your brand from the moment the box arrives:

• Full-color offset and digital printing
• Interior printing for a branded unboxing experience
• Spot UV and foil accents for extra visual impact
• Logo and text placement tailored to your layout

Add-ons

Enhance usability and appeal:

• Self-locking flaps for quick and secure assembly
• Tear strips for customer convenience
• Custom inserts to hold contents snugly
• Matte, gloss, or soft-touch coatings for aesthetic appeal

Types of Chipboard Mailer Boxes

We produce solutions for a wide range of industries:

• Subscription box mailers – For monthly product deliveries
• Retail-ready mailers – Dual-purpose as packaging and display
• Sample kit mailers – Compact and sleek for promotional items
• Eco-friendly printed mailers – Fully recyclable with soy-based inks

3Ps of Mailer Packaging Functionality

Presentation

Chipboard offers a smooth printing surface, ensuring your branding is sharp and professional from the outside in.

Preservation

Despite being lightweight, chipboard offers reliable structural integrity that keeps contents protected from bends and bumps.

Protection

Each box is die-cut and scored to create reinforced flaps and edges, ensuring durability during transit and handling.

Upgrade to High-Impact Mailers

Choose foil stamping, interior color printing, or water-resistant coatings to stand out from generic packaging and build brand loyalty.

Why Choose Custom Boxes Lab?

We provide expertly designed chipboard mailers that meet your functional, branding, and budget needs. Whether you’re a startup or shipping at scale, we deliver smart, eco-conscious packaging—fast.

Get a Quote Today

Ready to upgrade your mailing game?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.