Shipping Mailer Boxes

More Than a Shipping Box — It’s a Branded Experience

From inbox to unbox, your customers should feel your brand in every fold, flap, and finish.

Tough Materials, Built for Transit

We use corrugated cardboard engineered to survive drops, tosses, and cross-country journeys.

• E-flute or B-flute corrugation for light to heavy items
• Single or double-wall options for added durability
• Kraft brown, white, or fully printed inside and out
• FSC®-certified and eco-friendly materials available

Tailored Sizes & Styles for Every Product

No more oversized boxes or crushed contents — we custom-fit every order.

• Standard mailer styles: tab-lock, roll-end tuck-top, auto-lock
• Popular sizes: 6×4×2″, 9×6×3″, 12×9×4″, or made-to-measure
• Flat-pack for storage & fast assembly when ready to ship
• Add custom inserts, partitions, or product trays

Custom Printing That Makes Your Mailer a Marketing Tool

Your box isn’t just a container — it’s a conversation starter.

• Full-color CMYK or Pantone spot printing
• Matte, gloss, soft-touch, or natural kraft finishes
• Inside printing available for surprise branding moments
• Add logos, slogans, QR codes, social handles & more

Add-Ons That Enhance Unboxing & Drive Engagement

Create moments worth sharing — and selling.

• Custom tape, tissue paper, and thank-you cards
• Foil stamping, embossing, or spot UV accents
• Perforated tear strips or thumb notch openings
• Printed instructions, promo inserts, or reorder incentives

The 3Ps Approach

Presentation

Our mailer boxes turn every delivery into a branded billboard — from the doorstep to Instagram.

Preservation

Durable, crush-resistant walls protect your product through shipping, storage, and handling.

Protection

Secured closures, custom inserts, and optional double-wall builds keep your items safe and snug in transit.

Why 5,000+ ECommerce Brands Trust Custom Boxes Lab

Because we turn ordinary shipping into extraordinary branding.

• Low MOQs — ideal for startups, DTC launches & subscription kits
• Free dieline setup & design support
• Fast U.S. production & delivery
• Eco-conscious packaging solutions available
• A creative team that understands shipping, scale, and storytelling

Let’s Build Mailer Boxes That Deliver More Than Products

Whether you’re launching a new brand, scaling fulfillment, or building your influencer kit — we’ll help you create shipping mailer boxes that protect, promote, and perform. Call us at 0000 or email today to start your order with Custom Boxes Lab.

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.