Corrugated Mailer Boxes

Packaging That’s Durable, Lightweight & Shipping-Ready

Ideal for small to medium-sized shipments, our mailer boxes are built to withstand shipping stress while maintaining brand integrity.

Premium Materials Engineered for Protection

We use high-quality corrugated board designed to cushion and secure your products.

• E-flute or B-flute corrugated cardboard – Offers excellent strength without added weight
• Natural kraft or white kraft liners – Choose rustic or clean finishes
• Optional moisture-resistant coatings – Added protection for sensitive products
• Smooth surfaces for vibrant, high-resolution printing

Custom Sizes & Styles to Fit Your Product Range

We tailor corrugated mailer boxes to your exact product dimensions and shipping needs.

• Tuck-top or auto-lock bottom designs for secure closure
• Flat-foldable for efficient storage and shipping
• Custom dielines for irregular shapes or multi-item kits
• Optional inserts for product stability and organization

Branding & Printing That Elevate Your Packaging

Make your mailer box a powerful marketing tool with eye-catching design.

• Full-color CMYK or Pantone printing options
• Space for logos, handling instructions, and promotional messaging
• Matte, gloss, or soft-touch finishes to suit your brand identity
• QR codes for enhanced customer engagement

Functional Features for Easy Shipping & Unboxing

Designed to simplify logistics and delight customers.

• Tear strips or easy-open tabs for convenience
• Self-locking flaps for secure transport
• Space for return labels or postage
• Eco-friendly and recyclable materials available

The 3Ps of Corrugated Mailer Box Packaging

Presentation

Clean, branded design that makes your package stand out upon arrival.

Preservation

Strong corrugated structure and coatings protect contents during shipping.

Protection

Reliable closures and cushioning prevent damage and loss.

Why 5000+ eCommerce & Retailers Trust Us

From startups to large brands, we deliver dependable, branded packaging solutions.

• No minimum order requirements
• Free mockups and dielines for easy design approval
• Fast production and U.S.-based shipping
• Sustainable packaging options
• Dedicated support for your packaging needs

Get a Free Quote Today

Ship with confidence and style. Call 0000 or email us to start your corrugated mailer box project with Custom Boxes Lab—where packaging meets performance.

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.