Postage Mailer Boxes

Packaging That’s Secure, Lightweight & Shipping-Optimized

Perfect for online sellers, subscription boxes, and small product shipments, our mailer boxes safeguard items with style and efficiency.

Strong Materials That Withstand Transit

We use premium, corrugated materials designed for protective shipping without excess bulk.

• E-flute or B-flute corrugated board – Balances strength with lightweight design
• White kraft or natural kraft finishes – Choose clean or eco-friendly looks
• Moisture-resistant coatings – Optional for added protection
• Smooth surfaces for high-quality printing

Custom Sizes Tailored to Your Shipping Needs

Whether you ship cosmetics, apparel, electronics, or small goods, we size your mailer boxes for a perfect fit.

• Standard tuck-top or auto-lock mailer designs
• Flat-foldable for efficient storage and shipping to your fulfillment center
• Custom dielines for unique product shapes or multi-item kits
• Optional inserts for product protection and organization

High-Impact Printing That Builds Brand Recognition

Turn your packaging into a marketing tool with vivid, professional print.

• Full-color CMYK or Pantone spot-color printing
• Space for logos, shipping instructions, or promotional messaging
• Matte, gloss, or soft-touch finishes for a premium feel
• QR codes linking to your website, tracking, or special offers

Functional Features That Simplify Shipping & Unboxing

Designed with both your logistics and your customers in mind.

• Tear strips or easy-open tabs for convenient access
• Self-locking closures for secure transit
• Space for return labels or postage stamps
• Recyclable and eco-friendly materials available

The 3Ps of Postage Mailer Box Packaging

Presentation

Clean, professional design that makes your brand memorable upon delivery.

Preservation

Durable construction and moisture resistance keep products safe during transit.

Protection

Strong corrugated material and secure closures prevent damage and loss.

Why 5000+ eCommerce & Retail Brands Trust Us

From startups to established sellers, we provide reliable, branded shipping solutions.

• No minimum order quantity
• Free custom mockups and dieline assistance
• Fast turnaround and U.S.-based shipping
• Sustainable packaging options
• Dedicated packaging experts to support your project

Get a Free Quote Today

Ship your products with confidence and style. Call 0000 or email us now to begin your postage 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.