Foldable Mailer Box

Designed for eCommerce, Gifting & Subscription Kits

Whether you’re a beauty brand, fashion retailer, or lifestyle startup, these boxes offer sleek presentation and postal efficiency:

• Apparel and fashion accessories
• Subscription boxes (beauty, snacks, grooming, etc.)
• Promotional influencer mailers
• Gift sets and sample packs
• B2B welcome kits or onboarding packages

Premium Materials That Balance Strength & Style

We craft each foldable mailer from sturdy yet flexible materials, ensuring your items arrive safely and in style:

• Corrugated cardboard: Lightweight and protective for transit
• Kraft board: Natural and sustainable with a rustic appeal
• White SBS: Clean surface ideal for bold branding
• Protective coatings: Moisture-resistant and scratch-proof finishes available

Custom Styles That Fold Flat & Pop Up Fast

Our boxes are engineered for easy setup, space-saving storage, and high-impact display:

• One-piece self-locking mailers
• Fold & tuck-style closure
• Magnetic or adhesive closure options
• Die-cut front flaps, handles, or thumb notches
• Glued auto-lock bases for quicker assembly

Brand-Forward Customization That Converts

Make your foldable mailer a true brand experience with full customization:

• Full-color printing inside & out
• Foil stamping, embossing, or debossing
• Printed inserts for marketing or product protection
• Interior thank-you notes, care instructions, or welcome messages
• QR codes for brand videos, promotions, or reorder links

Small Details, Big Impact

Upgrade the unboxing experience with thoughtful additions:

• Custom stickers and seals
• Printed tissue paper or shredded fill
• Fold-in flaps with messaging
• Belly bands, ribbons, or sleeves
• Inner packaging compartments or divider panels

The 3Ps of a Great Mailer Box

• Presentation: Clean lines, vibrant printing, and a sleek reveal.
• Protection: Tough materials that guard your goods in transit.
• Practicality: Fold-flat construction for lower shipping and storage costs.

Why Brands Choose Custom Boxes Lab

We help businesses of all sizes deliver premium packaging that leaves a lasting impression.

• No minimum order quantities
• Free dieline creation & 1-on-1 design support
• Fast U.S. shipping & production
• 100% customizable styles & finishes
• Eco-friendly packaging solutions available

Get a Free Quote Today

Looking for foldable mailer boxes that combine functionality and flair? Contact Custom Boxes Lab for a free quote. We’ll help you design packaging that ships efficiently and showcases your brand with every delivery.

Call 0000 or email us now to begin your foldable packaging journey.

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.