Mailer box
Mailer boxes
Self-locking corrugated boxes that ship without an outer carton and open like a lid.
Corrugated
Mailer box · Corrugated
Custom ecommerce packaging
Ecommerce packaging is a printed box that ships your product on its own, with an insert that stops it moving. The usual choice is a corrugated mailer, printed inside and out, from 50 units per design. We draw the structure 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
- Box
- Mailer or shipping box
- Board
- Corrugated
- Best for
- Parcels and subscriptions
- Best value starts at
- 50 units
- Typical production window
- 10–12 days
- Quote reply time
- 12–24 hours
- For structural design
- $0
Overview
What does ecommerce packaging include?
The catch is that a delivery truck isn't a shelf. A retail carton in the mail arrives crushed, and a rigid box needs another box around it. Size the box snug, because empty space is billed to you as dimensional weight.
Three layers do three jobs. An outer box survives the carrier, an inner box or insert holds the product still, and a printed lid or card is what the customer remembers. Often one mailer does all three.
Pick the box from the product's weight and fragility, then decide how much print to put on it. For most small brands, a printed mailer with a printed lid interior is enough.
- Mailer box. Self-locking corrugated, printed inside and out. See custom mailer boxes.
- Shipping box. A corrugated carton for heavier items. See custom shipping boxes.
- Insert. Paperboard or corrugated, cut to the product.
- Tissue and a card. Cheap, and the part people film.
Specifications
Custom ecommerce packaging: 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 |
|---|---|
| Style | Mailer box, shipping box or telescoping corrugated box |
| Board | Corrugated, E-flute or B-flute |
| Outside, and inside of the lid | |
| Inserts | Paperboard or corrugated, cut to the product |
| Add-ons | Tissue paper, a printed card |
| Size | Drawn to your product |
| Ships to you | Flat, packed in cartons |
| Recyclability | Corrugated recycles with the box, inks and aqueous coating included |
| Order size | Best value from 50 units per design, because of logistics and shipping. Smaller orders can be considered |
| 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 box for which product?
Pick by weight and how fragile the product is.
| Product | Box | Why |
|---|---|---|
| Apparel, light goods | Corrugated mailer | Ships on its own, no outer carton |
| Heavy or bulky | Corrugated shipping box | Stiffer board and bigger sizes |
| Fragile | Mailer with a cut-to-fit insert | Product doesn't move |
| Gifts | Rigid box inside a plain mailer | Rigid doesn't ship bare |
Most brands use one mailer size and fill the space with paper on lighter orders.
Compare
Mailer box or poly mailer?
Poly mailers are cheap. A box is stiffer and carries more print.
| Mailer box | Poly mailer | |
|---|---|---|
| Protects | Corners and contents | Contents from water, little else |
| Inside and out | Outside only | |
| Recycles with cardboard | Yes | No |
| Best for | Fragile or gift products | Soft goods, low cost |
Poly mailers aren't something we make. If your product is a T-shirt and margins are tight, they may be the right call. See custom subscription boxes for repeat shipments.
Sizing
Sizing for the carrier
Carriers bill on the greater of actual and dimensional weight. UPS divides length x width x height by 139 on daily rates, or 166 at retail, and rounds up. A box with air in it costs more to ship.
Send the product's size as packed and the carrier you use. See shipping box sizes and how to measure a box.
Who uses custom ecommerce packaging
- Direct-to-consumer brands. A printed mailer is the first thing customers touch. See custom apparel boxes.
- Subscription brands. The same box ships every month. See subscription packaging.
- Dropshippers with their own brand. Print runs from 50 units keep stock small.
- Small shops testing a product. See custom packaging for small business.
Finishes
Print the lid interior, skip the rest.
Most ecommerce boxes need one finish, not four. Aqueous coating goes on every box by default.
Aqueous coating
Water-based and on every box by default. It recycles with the box.
Spot UV
Gloss on one area of a matte box. Good for a logo, bad for small text.
Debossing
Pressed in, no ink. Works on kraft as well as white board.
Quote
Get a quote for custom ecommerce packaging
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 ecommerce packaging: questions.
What is the minimum order for ecommerce boxes?
Best value starts at 50 units per design, because of logistics and shipping. If you need fewer, tell us: we can consider smaller orders.
How long do ecommerce boxes take?
10–12 days on most orders, counted from proof approval. Shipping time is on top and depends on where the boxes are going.
Do you charge for structural design?
No. Structural design is $0. We draw the dieline around your product, and you only pay once you order boxes.
What is the best box for ecommerce?
A corrugated mailer sized snug to the product, printed inside and out. It ships on its own and opens like a lid.
Can you drop-ship the boxes to my fulfillment center?
Yes. Boxes ship flat, packed in cartons, to wherever your orders are packed. Tell us the address when you order.
Are the boxes recyclable?
Corrugated recycles with the rest of the box. Skip lamination and window film if recyclability matters.
Honest fit
When not to hire us.
You ship under 50 orders a month
A plain stock mailer with a printed sticker will cost you less. Custom pays once the box carries your brand across more orders than that.
You only need a handful of boxes
Best value starts at 50 units, because of logistics and shipping. For 10 or 20 we can consider it, but the cost per box is higher and a stock box with a printed sticker may 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 as packed and how many orders a month you expect. We'll name the box.
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
Mailer box
Subscription boxes
Mailers printed inside and out, so the first thing people see is the inside of the lid.
Corrugated
Shipping box
Cardboard boxes
E-flute and B-flute corrugated boxes printed with your logo and sized to the product.
Corrugated