Original price was: $1.50.$0.30Current price is: $0.30.
Custom Size & Style
Free Shipping
Quick Turnaround Time
No Minimum Order Required
No Die & Plate Charges
Free Graphic Designing
Custom mailer boxes have become a go-to packaging choice for brands that ship products regularly, especially in eCommerce packaging solutions in the USA. They’re sturdy, versatile, and designed to protect items while still offering room for branding and presentation. Whether you’re sending subscription kits, apparel, cosmetics, accessories, or promotional packages, custom mailer boxes let you deliver a clean and branded package the moment your customer receives their shipment.
For businesses offering beauty or retail products, pairing mailers with Custom Cosmetic Boxes or Custom Apparel Boxes ensures consistent brand presentation across all packaging formats.
Pack-Edge Printing has a strong reputation for custom printed mailer boxes in the USA. Our boxes are built to be durable, visually appealing, and suitable for each product’s needs. They focus on structural strength, print accuracy, and materials that support both shipping and retail-ready presentation. For businesses that rely on dependable packaging, mailer boxes offer the perfect balance of practicality and branding. You can also explore our full range of Custom Product Boxes for additional packaging styles.
Unlike standard shipping boxes, mailer boxes are designed with both structure and presentation in mind. They are typically made from corrugated boards, which are strong enough to withstand drops, vibrations, and handling during transit. The most common style is the tuck-top mailer, which folds together without adhesives but still holds its shape securely.
Their clean structure makes them a favorite for subscription box packaging and branded shipping boxes. Mailer boxes also offer multiple printing options, giving businesses the freedom to customize both the inside and outside of the box for a polished unboxing experience.
One of the biggest reasons mailer boxes are so popular is their reliability during shipping. Corrugated materials absorb impact and offer better protection than thin packaging. For companies sending products monthly or seasonally, custom mailer boxes help ensure a consistent customer experience.
They also reduce the need for extra padding or complicated wrapping. With a secure, self-locking design and the option for inserts, custom mailer boxes can be tailored to fit the product precisely. This helps prevent damage while also keeping the package organized. Businesses shipping retail items can also combine them with Custom Retail Boxes for in-store and shipping consistency.
Over time, several designs have become standard for mailer-style packaging. You can opt for any type based on your packaging goals. For your ease, we have listed the most popular types below:
Finishing touches help strengthen your brand identity and improve the unboxing experience. Our custom mailer boxes can include:
Pack-Edge Printing produces custom shipping boxes and corrugated mailer boxes in the USA crafted for strength, print quality, and reliable performance during transit. We help brands choose the right materials, styles, printing options, and inserts that match their products and shipping requirements. From bold branding to minimal designs, we offer a range of solutions built to withstand real-world shipping conditions.
On top of everything, we make it super easy for you to choose preferences and place your order for custom mailer boxes. Get a quote right now to get started and explore our complete Custom Packaging Boxes collection.
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
|---|---|
| Dimensions | Available in all Custom Sizes |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Cardboard, Eco-friendly Kraft, E-flute Corrugated, Bux Board |
| Options | Window Cut Out, PVC Sheet, Gold/Silver Foiling, Foil stamping, Raised Ink, Spot UV, Embossing, Debossing |
| Quantities | Starts from 50 to Unlimited |
| Printing | CMYK, PMS, Without printing, Off-set printing, Digital printing |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Coating | Gloss, Matte, Soft Touch Matte Lamination, and Varnish |
| Turn-Around Time | Regular (5 to 8 Business Days to ship), Rush order (On Request) |
UV Coating
This is a liquid layer that we dry with special lights to give your packaging a very shiny finish.
Aqueous Coating
This is a fast drying water based layer that protects your boxes from fingerprints and scratches during the shipping.
Lamination
We apply a thin plastic film over the paper to make your boxes strong and keep them from ever tearing.
Soft Touch Lamination
This special film makes your box feel as soft as silk and gives your brand a very high-end feel.
Spot Gloss UV
This shiny coating is put only on certain parts of the page to make specific pictures or words pop.
Varnish
A clear ink used to protect the page or add a light shine, though it can yellow over time.
Anti-Scratch Lamination
A tough plastic shield that prevents ugly scuffs and marks from ruining your product when people touch it.
Silk Lamination
This coating makes the paper feel very smooth and expensive, while also making it much harder to tear.
Offset Printing
This method uses big metal plates to transfer ink onto paper and creates very sharp images for large orders.
Digital Printing
This works like a fast computer printer and is best for small orders that need many different bright colours.
Flexographic Printing
This process uses flexible rubber stamps and fast-drying ink, which is perfect for printing on very long paper rolls.
Screen Printing
We push thick ink through a fine mesh screen to create bold designs that feel raised on your custom packaging.
CMYK Printing
This method uses four ink colors—cyan, magenta, yellow, and black—to create almost any color you can imagine.
Pantone Printing
This system uses pre-mixed ink colors to make sure every single print looks exactly the same every time.
Metallic Ink
This special kind of ink has tiny bits of metal inside to make your printed designs look shiny.
Full-Color Printing
Using many colors at once allows you to print beautiful, bright photos that look very realistic and clear.
Embossing
This method uses a special tool to push the paper up, creating a raised design that you can easily feel.
Debossing
This process presses your design deep into the material to create a cool sunken look that feels very high class.
Foil Stamping
This process uses heat to press shiny metallic colors like gold or silver onto paper to make designs really sparkle.
Holographic Foiling
This special foil reflects many different colors like a bright rainbow when the light hits it from a certain angle.
Spot UV
This clear and shiny coating is applied only to certain parts of the page to make specific details stand out.
Matte Finish
This smooth coating provides a soft look without any shine, making the surface feel very velvety and easy to read.
Gloss Finish
This very shiny layer reflects a lot of light and makes the colors on your paper look bright and exciting.
Window Patching
We cut a hole and add clear plastic so your customers can see the product inside without opening the box.
Kraft Paper
This is a tough, brown material made from wood pulp that people often use for grocery bags and boxes
SBS Paperboard
This high-quality white board is very smooth on both sides, making it perfect for printing bright, colorful food packaging.
Coated Paper
This paper has a special clay layer that makes it feel smooth and look shiny for high-quality picture books.
Uncoated Paper
This natural-feeling paper has no extra finish, so it absorbs ink easily and is great for writing with pens.
B-Flute
This strong, medium-sized cardboard resists crushing and works perfectly for mailing boxes that need to stay very safe inside.
C-Flute
As the most common shipping choice, this thick layer provides good cushioning for everyday items moved in large trucks.
F-Flute
Being the thinnest option available, this lightweight paper is used for tiny specialty boxes like jewelry or fast food.
E-Flute
By stacking two different layers together, this extra thick board creates a heavy-duty box for shipping very heavy items.
800gsm
This material is thin but strong enough to hold its shape well for small, lightweight boxes and sturdy cards.
1000gsm
A great middle-ground choice that feels very solid and provides good protection for most standard types of gift boxes.
1200gsm
This thick board feels heavy in your hand and is the most popular choice for high-quality, durable luxury packaging.
1400gsm
This is a very tough and rigid material used for larger items that need extra support to stay safe.
Samantha C.
Catering Business
Samantha C.
Catering Business
Samantha C.
Catering Business
Samantha C.
Catering Business
Samantha C.
Catering Business
We strive to accommodate your order between 8 to 10 business days, but multiple factors are involved in the process. Product line for which you need packaging
Absolutely, yes, no matter which packaging type you contact us for, you will experience earth-friendly packaging material in every purchase. We take pride in our services, and this is one of them; our consults acknowledge us for serving them sustainable options.
We offer you boxes at wholesale price with a minimum order limit of 50 boxes. Plus, design and material consultation and shipping all over the USA services automatically cut down the overall cost. You can also contact a customer representative to enjoy custom packaging at the minimum possible rate.
Absolutely, yes, no matter which packaging type you contact us for, you will experience earth-friendly packaging material in every purchase. We take pride in our services, and this is one of them; our consults acknowledge us for serving them sustainable options.
You do not have to worry about it; all popular payment methods, Visa to Master card payment, Amex to Discover, and PayPal, are acceptable.
Our team will send you a design file for final approval. You can also ask for physical sampling for better assessment. This is done to remove possible bugs in packaging design, material, and printing. After the assessment process, production has started.
