Mailer Box

#1 Best Seller

Popular for e-commerce & subscription

Easy-to-assemble one-piece design

Shipping-ready & crash-resistant see more

Box Options & Prices

Interior Size

3 to 22

3 to 35

1.01 to 9

Quantity

1 to 200000

Design

Download dieline
Upload
PDF
OR
Design
online

Custom Size

Box for anything from a diamond ring to a mattress.

Quantity 1+

No minimum order quantity. Order one or thousands.

Design in 3D

Design online or upload PDF. Interactive 3D preview.

High Quality

Best in class full color digital printing.

$30 Sample

Get a box with your own design, delivered fast.

Live Support

Customer service is one mouse click or phone call away.

Overview

aka REFT, Roll End Front Tuck with Dust Flaps and Cherry Locks, FEFCO 0427

Mailer box is our most popular box style. It's used by e-commerce, retail, subscription, PR kits and many other types of businesses.

  • Easy-to-assemble one-piece design
  • Shipping-ready and crash-resistant
  • Shelf-ready and safely stackable

Dimensions

aka box size

Basics

  • All our boxes are cut to a specific size.
  • Box dimensions are inside dimensions.
  • Box dimensions are measured in inches.
  • Box dimensions are listed as Length x Width x Depth.
  • Length (L) is measured left to right.
  • Width (W) is measured front to back.
  • Depth (D) is measured top to bottom.

Size restrictions

  • Depth cannot be greater than Length.
  • Minimum dimensions: 3 x 3 x 1"

Interesting observations

  • 50 sizes cover 90% of known use cases
  • 80 sizes cover 99% of known use cases
  • Average mailer box proportions are 10:8:3
  • 28% of mailer boxes are square (L = W)
  • 1% of mailer boxes are cubes (L = W = D)
  • Width is usually 50-100% of Length
  • Depth is usually 11-50% of Length
  • Sizes typically range from 4 x 4 x 1 to 24 x 18 x 6
  • Fractional sizes are used in less than 20% of cases
  • Shipping labels (3x6 to 4x6) often placed at the bottom

Material: Corrugated Board

aka corrugated cardboard, corrugated fiberboard

Corrugated board is a light and strong material made from a flute corrugated sheet placed between one or two flat liners. The flute corrugated sheet in the middle is kraft. There are kraft, standard white and premium white options for the external liners. Both sides are printable, but the end result depends on both material and design.

Kraft

Uncoated, unbleached natural kraft surface.

Brown outside and inside with matte finish. UV LED inks. Inks may appear lighter or darker than their CMYK color value on kraft material.

Colors look different on Kraft

Darker colors work better on Kraft.

Light colors do not print accurately on Kraft because they need a bright white background.

White ink does not print, so instead of white you will see kraft, the color of material.

Standard White

aka Mottled White

Uncoated white, with natural kraft undertones. The standard white board.

Mottled white outside and inside with matte finish.

Standard White costs the same as Kraft.

Premium White

Our brightest coated white outside and inside with matte finish.

Premium White costs about 10% more than Standard White or Kraft.

Premium White with Gloss Finish

Our brightest coated white outside and inside with high gloss finish on printed ink.

Premium White with Gloss Finish costs about 10% more than Premium White, and about 20% more than Standard White or Kraft.

Printed Sides

PackM offers boxes printed outside, inside or outside & inside or left blank.

Mailer boxes can be printed outside, inside or on both sides. Mailer boxes are known for very creative designs and fun unboxing experiences, so pick what works best for your brand.

Print Outside

Most custom mailer boxes have a design printed outside. Almost all boxes have a logo on one or several sides.

Shipping Label

Many mailer boxes leave some room for a shipping label. USPS preferred shipping label sizes are 4x6", 3x6" and 4x4".

Print Inside

A number of mailer boxes only have printing inside. This is often used for personal products where discrete packaging is important.

Costs 25% more than printing on the outside only.

Print Outside & Inside

Many mailer boxes add branding or messages inside the box to improve the unboxing experience.

Hint: Because of the mailer box construction its left and right side flaps end up inside the box when it's assembled, so if you only place content there, you won't have to pay premium.

Printing on both sides costs about 60% more than printing on the outside only.

Blank boxes

There are many reasons why one might need blank boxes. Usually blank boxes are ordered for a specific custom box size.

If you need blank boxes, design your box online, leave it blank, and proceed to order. We will contact you to confirm that you really are ordering blank boxes.

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FREE
Graphic Design
Assistance

Reach out to our Live Chat and take advantage of this complementary offering. Whether you need help adjusting print-ready files or need overall support properly adding artwork to our dielines.

Sample box
with your design
ships in 2-5 days

Get a single box sample to see print quality and make sure that dimensions work well with the box contents, get a sample box with your design for as little as $30.

Orders up to 4 boxes are considered samples, produced faster and usually ship within 2-5 business days.

Mailer Box FAQ

What is the minimum order size?
1 box.
Where are mailer boxes printed?
All mailer boxes are produced in the United States. To minimize shipping cost, PackM produces boxes at the facility closest to the shipping destination.
Is it easy to assemble a mailer box?
Mailer box is one easiest types of boxes to assemble. PackM ships printed mailer boxes flat and ready for assembly. It takes a 3-10 seconds to fold, snap and tuck a mailer box.
How to choose a mailer box size?
Measure what goes inside the box, add 0.125" for a snug fit, or 0.25" for comfortable fit. Box dimensions are interior, so you don't have to worry about thickness of the material. If you leave less space, your content might not fit. If you add more that 0.25" then some void fill materials—such as bubble wrap, foam rolls or packing paper—might be required to fill out the remaining space and protect your box content.
Can I get a sample of my box before placing a full order?
Yes! It's very common to order a sample of box, especially if it's a first order. PackM offers a low all-inclusive price of $30 for 1 sample box with your custom specs and design, with free shipping in the United States. Configure your product and select quantity = 1 to order a sample. Most samples are produced and shipped within 2-5 business days.
Can I use a mailer box as a subscription box?
Yes! Using mailer boxes as subscription boxes is one of many use cases. Mailer boxes are perfect choice for a subscription box, because it's easy to assemble, very sturdy and can be made in a wide range of sizes, from 3x3x1 to 18x18x7 inches. In addition to subscription boxes, mailers are often used for shipping gifts, promo kits, e-commerce orders etc.
How to design a mailer box?
Easy! PackM offers 3 ways to design a great mailer box. You can design it online in PackM design editor and view interactive 3D preview of your box as you design. Upload your logo and images, add text and shapes, use any color you want.
Can you design a box with my logo?
The fast and free solution is to design your box online. Select size, material and click design online above. The slower but still free is to ask PackM designer to create a box design.
Does PackM check my files?
Yes! PackM checks 100% of customer files (both designed online, and uploaded) to make sure that everything is ready for printing. Every file is carefully inspected by packaging prepress expert. PackM can make micro-adjustments to meet specific production equipment requirements.
How can I pay for my order?
PackM accepts Visa, MasterCard, American Express and other popular payment cards. PackM doesn't store customer credit card data, and uses industry-leading payment processor - Braintree, a PayPal service - to process payments. Braintree secure and advanced technology makes it possible for PackM customers to save their credit card information for future use (even in those cases PackM doesn't have access to customer payment info and doesn't store it on its servers). If you need a payment method that PackM doesn't yet offer, please contact customer service.
What parts of the box are printable?
100% of the box surface is printable. Outside printing covers outside top, bottom, left, right, front and back sides, as well as inside left and right (because those parts are actually outside folded inside the box). Inside printing covers inside top, bottom, front and back (left and right panels are covered and usually don't have any meaningful design elements).
Do more colors and bigger print area cost more?
No. More colors and bigger print area will cost the same. PackM encourages its customers to use as many colors as you want.
Are there any hidden charges?
No. PackM charges customers for printing and shipping cost, plus collects taxes (we don't keep them).
Do I get a discount if I order more?
Yes. The more you order, the lower is your unit price (price of one box). PackM is happy to pass savings to customers, when it costs us less.
Can I order a blank mailer box?
Yes. Choose design online option, add it to cart, and place an order.
When will I receive my boxes?
Yes. Most orders are produced and shipped within 4-15 business days.
Can I reorder my boxes?
Yes. You can reorder as-is, or change design, specs, quantity.

Set Your Brand Apart with Custom Mailer Boxes

With the perfect packaging, custom-made to suit your product needs, your product is guaranteed to not only look even more presentable, but also feels good to unbox. The custom mailer box is designed according to your exact specifications, increasing your presentation value by making sure that the packaging matches the product.

Customize Mailer Boxes Online

Get creative with our easy-to-use “Design Online” feature and design your box using 3D modeling. With our in-site application, you can select from a wide variety of templates or choose to start from scratch. You can freely configure the dimensions and material of the box (standard white, premium white, and kraft), as well as the print design on both the inside and outside of the box. And the best part? Adding more designs and creating a greater print space won’t cost you more, so you can get as creative as you want. Alternatively, if you already have a prepared design, you can simply upload it to personalize your box. After making your finishing touches, you can order samples to make sure that your box looks and feels perfect.

Keep Your Items Secure

These roll end front tuck custom mailer boxes are perfect for both shipping and standing out on the shelf. Your products will remain safe in transit, with the use of durable corrugated cardboard, giving you peace of mind with another satisfied customer. The Mailer Box can be used for a variety of products, ranging from e-commerce orders, electronics, and beauty products to subscription boxes and promotional kits.