Custom Mailer Boxes With Inserts

Why Mailer Boxes + Inserts Are the Ultimate Combo

Inserts turn an ordinary mailer box into a complete branded experience. They:

• Hold products firmly in place to avoid damage
• Organize multiple items neatly for professional presentation
• Add a layer of luxury for gift sets, influencer kits, or subscription boxes
• Reduce returns and increase customer satisfaction

This packaging is ideal for:

• Beauty and skincare products
• Apparel and accessories
• Tech gadgets and electronics
• Candles, glassware, and breakables
• Corporate welcome kits and promotional sets

Custom Inserts for a Custom Fit

No two products are the same—and your inserts shouldn’t be either. We offer:

• Die-cut cardboard inserts – Lightweight and eco-friendly
• Foam inserts – Premium feel and maximum shock absorption
• Molded pulp trays – Sustainable and biodegradable
• Multi-compartment layouts – For product kits, accessories, or sample packs
• Removable or glued-in options – Flexible depending on your workflow

Each insert is designed to perfectly match your product’s shape and size, ensuring it ships safely and looks sharp.

Mailer Boxes That Ship Strong and Look Better

Our custom mailer boxes are made from durable corrugated board and fully customizable inside and out:

• Tuck-top, front-lock, or tab-lock designs
• E-flute or B-flute for light to heavy products
• White, Kraft, or black base options
• Flat shipping for space-saving storage
• Optional thumb holes or pull-tabs for ease of use

Add inserts, and you’ve got a complete packaging solution that looks high-end and holds up during transit.

Full Custom Printing to Match Your Brand

You’ve built a brand worth showing off—so don’t stop at the product. We offer:

• Full-color CMYK or Pantone printing
• Custom inserts with branding or messaging
• Gloss, matte, or soft-touch finishes
• Foil stamping, embossing, or spot UV for premium accents
• QR codes, promos, and thank-you messages inside the lid

Use every inch of your box and insert to connect with customers—before they even see the product.

Performance Features You’ll Appreciate

• ✔ Easy to assemble
• ✔ Insert-ready design for fast fulfillment
• ✔ Eco-friendly and recyclable materials available
• ✔ Perfect for retail, gifting, or direct-to-consumer shipping
• ✔ Great for influencers, unboxing videos, and social sharing

The 3P Promise: Protection. Presentation. Professionalism.

Protection

Inserts prevent shifting, scratching, and damage during shipping.

Presentation

A clean, organized interior elevates your brand’s perceived value.

Professionalism

Everything from the box to the insert reflects the quality of your product.

Why Choose Custom Boxes Lab?

We’re the go-to source for businesses that want packaging that works and wows:

• No order minimums
• Fast turnarounds and low MOQs
• Free dieline templates and design assistance
• Bulk pricing for large runs
• U.S.-based service and global shipping

Whether you’re a startup or an established brand, we make it easy to get packaging that fits, ships, and sells.

Get a Free Quote

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.