Mailer box
Mailer boxes
Self-locking corrugated boxes that ship without an outer carton and open like a lid.
Corrugated
Shipping box · Corrugated
Custom cardboard boxes
Custom cardboard boxes are corrugated boxes printed with your brand and sized to your product, from 50 units per design. We draw the box for free, and production takes 10–12 days from proof approval.
- Over 30 years in print and packaging
- Free structural design
- From 50 units
- Plastic-free options
- Board
- E-flute or B-flute corrugated
- Style
- Mailer, shipper, custom
- Best for
- Shipping, e-commerce
- Minimum order
- 50 units
- Typical production window
- 10–12 days
- Paper-first materials
- 100% recyclable
- For structural design
- $0
Overview
Cardboard, corrugated and paperboard
People say cardboard when they mean one of three things: corrugated, paperboard or rigid board. Pick the right one and the box survives the mail. Pick the wrong one and it arrives crushed.
Cardboard is a loose word. Corrugated is the fluted board shipping boxes are made of: a wavy paper layer between two flat liners. Paperboard is the thin, solid board of cereal boxes and retail cartons. Rigid board is the thick greyboard of gift boxes.
When you ask for custom cardboard boxes to ship a product, you almost always want corrugated. The flute is the part that takes the knocks. Flute types explains the letters.
- Outer liner. The printed face of the box.
- Flute. The wavy layer that gives strength and cushioning.
- Inner liner. White or kraft, plain or printed.
- Insert. Optional corrugated or paperboard piece that holds the product.
Specifications
Custom cardboard boxes: specifications
Every box is drawn to your product, so these are the options, not a fixed catalogue. Your specialist confirms the exact spec on the proof.
| Spec | Detail |
|---|---|
| Board | E-flute corrugated (roughly 1/16 inch per wall). B-flute (roughly 1/8 inch) for heavier products |
| Liner | White or kraft (brown) outside, white or kraft inside |
| Style | Mailer, flap-top shipping box, or a structure drawn to your product |
| Outside, inside, or both. One color to full color | |
| Inserts | Corrugated or paperboard, cut to your product |
| Add-ons | Tear strip, thumb notch, die-cut handle hole |
| Size | Drawn to your product |
| Recyclability | 100% recyclable corrugated. Skip plastic lamination to keep it that way |
| Minimum order | 50 units per design |
| Structural design | $0. We draw the dieline around your product |
| Proof | Digital proof on your dieline, checked for bleed, folds and barcodes |
| Production | 10–12 days on most orders, from proof approval. Shipping time is on top |
| Default finish | Aqueous coating on every box. Water-based, and it recycles with the box |
| Point of contact | One packaging specialist, from first sketch to delivery |
Board and build
Which flute for your cardboard box?
Most boxes are E-flute. Heavier products move to B-flute.
| Board | Looks like | Best for |
|---|---|---|
| White E-flute | Bright. Takes full-color print cleanly | Photos, pale brand colors |
| Kraft E-flute | Brown and natural. Ink prints darker | One or two strong ink colors |
| B-flute | Thicker wall, slightly softer print | Heavier products, glass |
Pale pink on kraft prints as beige, because the brown shows through the ink. If your brand color is light, use a white liner.
Compare
Cardboard box, mailer or shipping box?
Three corrugated styles. They open and close differently.
| Mailer box | Shipping box | Retail carton | |
|---|---|---|---|
| Board | Corrugated | Corrugated | Paperboard |
| Closes with | Tuck lid | Tape | Tuck flaps |
| Best for | Single items, subscriptions | Heavy or mixed orders | Retail shelves |
| Goes in the mail on its own | Yes | Yes | No. Too thin |
Details on each: custom mailer boxes, custom shipping boxes and custom folding cartons.
Sizing
Sizing a cardboard box
Send your product's exact length x width x height, plus anything else that goes in with it. We add clearance on the dieline, so don't add it yourself.
Size changes postage too. UPS bills on dimensional weight when it's higher than the actual weight, which is length x width x height divided by 139 on daily rates, per its shipping dimensions and weight guide. Shipping box sizes has a worked example.
Who uses custom cardboard boxes
- E-commerce brands. The box is the first thing a customer touches.
- Subscription boxes. See custom subscription boxes.
- Wholesale and fulfilment. A repeat size drawn once and ordered again.
- Food and drink brands. Tell us what goes in, and we specify food-contact board.
Finishes
One finish, on the logo.
Most cardboard boxes need one finish, not four. Aqueous coating goes on every box by default.
Aqueous coating
Default. Protects the print through the mail.
Foil stamping
One logo on the lid.
Debossing
Pressed in, no ink. Suits kraft liners.
Quote
Get a quote for custom cardboard boxes
One measurement and a quantity is enough to start. Your specialist replies with a structure, so you can see the box before you commit to anything.
How it works
Four steps, one person.
The specialist who picks up your first email stays with the project until the boxes arrive.
Step 01
Tell us what you're packing
Send the product dimensions, how it ships and how many you need. A photo on a ruler is enough to start.
Step 02
We draw the structure
Your packaging specialist builds the dieline around your product. Structural design is free.
Step 03
You approve the proof
Drop your artwork onto the dieline. We check bleed, folds and barcodes, and send a digital proof.
Step 04
We make and ship
Production takes 10–12 days on most orders. Boxes ship flat, packed in cartons, to your door.
FAQ
Custom cardboard boxes: questions.
What is the minimum order for custom cardboard boxes?
50 units per design. That's enough to test a box with real customers before a bigger run.
What is the difference between cardboard and corrugated?
Cardboard is a general word. Corrugated is the fluted board shipping boxes are made of. Paperboard is the thin solid board of retail cartons. Most shipping boxes you want are corrugated.
Can you print on cardboard boxes?
Yes, outside, inside or both, from one color to full color. White liners take full-color print best.
Are custom cardboard boxes recyclable?
Yes. Corrugated is paper, and paper and paperboard had a 68.2% recycling rate in 2018 per the EPA. Plastic lamination reduces recyclability.
Which flute should I choose?
E-flute suits most products. B-flute is thicker and suits heavier ones. Your specialist will pick based on weight.
How long do custom cardboard boxes take?
10–12 days on most orders, counted from proof approval. Shipping time is on top.
Honest fit
When not to hire us.
Your sizes change every month
A custom box is drawn to one product. If your product mix keeps changing, stock boxes plus paper fill will cost you less.
You need fewer than 50 boxes
Our minimum is 50 units. For 10 or 20, a stock box with a printed sticker will cost you less.
You need boxes next week
Production runs 10–12 days before shipping. If your launch is sooner, buy stock boxes now and switch to custom for the next run.
You want plain brown boxes
If nothing gets printed, a stock box supplier is cheaper and faster. We're worth it once the box carries your brand.
What are you shipping?
Send the product's size, or a photo of it on a ruler, and how many you need. We'll come back with a structure and a proof.
Start a projectPopular boxes
Related boxes.
Shipping box
Printed shipping boxes
Standard flap-top cartons with your logo on the outside. Built for heavier orders.
Corrugated
Folding carton
Kraft boxes
Unbleached kraft cartons with one- or two-color print. Reads as natural without saying so.
Kraft
Mailer box
Subscription boxes
Mailers printed inside and out, so the first thing people see is the inside of the lid.
Corrugated