Custom Mailer Boxes
Branded self-locking boxes made for direct-to-consumer delivery.
What are mailer boxes?
Mailer boxes are self-locking corrugated boxes designed to ship directly to customers while delivering a branded unboxing experience — the go-to format for D2C and e-commerce brands.
Key features
- Self-locking, tape-free assembly
- Printed outside, inside or both
- E-flute corrugated for strength and print quality
- Custom inserts to hold products in place
- Tear strips and peel-and-seal options
Options at a glance
| Board | E-flute or B-flute corrugated, kraft or white liners |
|---|---|
| Styles | Roll-end tuck-front (RETF), double-wall mailers, mailers with tear strip |
| Printing | Outside, inside or both — single colour to full colour |
| Closures | Self-locking tabs, peel-and-seal adhesive strip, tear-open strip |
| Inserts | Paperboard or corrugated inserts to hold products in place |
| Use | Ship directly to customers without an outer box |
Best for
Why D2C brands love mailer boxes
A mailer box is both a shipping box and a presentation box. It locks shut without tape, survives courier handling on its own and opens to reveal a branded interior — so the unboxing becomes part of the product experience. For subscription brands, apparel, beauty and gifting, it is the single most effective way to make an online order feel premium.
Designing the unboxing
- Outside: keep branding bold and simple — it will be handled and scuffed in transit.
- Inside: this is where the magic happens; print a pattern, message or thank-you note under the lid.
- Inserts: hold each item in a planned position so the reveal looks neat every time.
- Extras: tissue, a printed card or a sticker seal complete the experience at low cost.
Returns-friendly options
A second peel-and-seal strip lets customers reseal the same mailer for returns, while a tear strip makes opening quick and tidy. Both reduce friction for customers and keep your returns process simple.
Frequently asked questions
What is a mailer box?
Can mailer boxes be printed inside?
Do mailer boxes need tape?
Which flute is best for mailer boxes?
Can mailer boxes be used for returns?
How do I get a price?
Helpful guides
E-commerce Packaging Guide: Reduce Damage, Returns and Shipping Costs
Right-sizing, volumetric weight, inserts and unboxing — how online brands build packaging that protects and sells.
Read article
Packaging Box Size Guide: How to Measure Your Product Correctly
Internal vs external dimensions, allowances for inserts and the L × W × H rule — get your box size right first time.
Read articleRelated packaging
Ready to Create Packaging That Gets Noticed?
Tell us about your product, packaging requirements, quantity and design preferences — our team will come back with options and pricing.