Our customer service team is open from 6 am to 5 pm on Thanksgiving and 5 am to 7 pm PST on Black Friday.
Production turnaround of Custom Mailer Boxes has temporarily increased to 25 Business Days due to high demand.

Mailer Boxes

4.7 (497)
Mailer Boxes - Custom Folding Cartons
  • Fast, easy assembly; no adhesive needed
  • Durable corrugated cardboard choices
  • Create a design online in minutes

Mailer Boxes That Elevate the Unboxing Experience

Custom Mailer Boxes Tailored to Your Specifications


Print mailer boxes that stand out as soon as they arrive on your customer’s doorstep. Your subscription boxes, e-commerce deliveries, or promotional kits can readily engage with a colorful and crisp representation of your brand on the packaging.

Custom mailer boxes provide all the advantages of having your products shipped. Its light weight makes it easy to assemble and affordable to have shipped. It's also made of durable corrugated cardboard that can withstand external forces while it's on-the-go. Your box can be created to fit the product size you need, allowing you to arrange them for the ultimate unboxing experience.

At NextDayFlyers, you can customize every detail of your mailer box printing: from its size, shape, material, and coating to the ordered quantity.

Popular Mailer Box Sizes

Choose from a wide range of custom mailer box sizes. The size you select refers to the interior dimensions:

  • Length: 3" – 25"
  • Width: 2" – 25"
  • Depth: 1" – 15"

 

4 Simple Steps to Order

1
Create your custom mailer box.

Select your preferred size, material, coating, and quantity.

2
Design your box.

Create your box on our intuitive design tool or have us send a dieline template based on your specs.

3
Approve your PDF proof. (optional)

If you opt to review your artwork before printing, we’ll send a free PDF proof of your design to approve before we proceed with printing.

4
Receive your order.

Box production takes about 20-25 business days. After this, the mailer boxes are shipped to your address.

Sturdy and Stylish Corrugated Cardboard Options

Your mailer boxes will be printed on durable corrugated cardboard. It protects the items it carries in transit. Plus your customers can recycle the box after they’ve received your package. There are 2 thicknesses depending on the size of your box: the thinner 1/16” E-Flute and thicker 1/8” B-Flute.

We offer two colors that suit everything from a minimalist to a rustic design:


Standard White Corrugated Cardboard
  • Comes in a smooth, uncoated finish
  • Thick enough to withstand multiple handling and delivery

Premium White Corrugated Cardboard With Glossy Ink
  • Print your design in extra shiny, high-gloss UV and complement it with a radiant white background
  • Perfect for designs with vivid details and colors

Kraft (Brown) Corrugated Cardboard
  • The default look and finish of corrugated cardboard
  • Perfect for natural or rustic-themed designs or products such as organic items

A Faster Process Every Step of the Way

Compared to traditional custom box manufacturers, NextDayFlyers produces your order faster from start to finish. See how soon your request will arrive with these typical times:


Stage NextDayFlyers Traditional Box Manufacturers
Quote instant several days
Design on our online tool, as fast as you like coordinate with a designer for weeks
Production 20-25 business days 1-2 months
Shipping ships directly from a US production facility ships from a factory across the world

Order a Sample Box

No minimum quantity is required. Set your quantity to 1 on the online calculator and place your order. We’ll produce and send a sample based on your specifications.


Mailer Boxes FAQs

Can I order a sample mailer box before committing to a larger quantity order?

Yes, you can order 1 mailer box that will be printed according to your size, material, design, and other printing specifications. Production time of samples will take between 5 business days.


How do I create a design for my mailer box online?

Our easy-to-use online design tool lets you create a box online with its simple and intuitive interface. Here you can add text, color, and images to the interior and exterior of the box. You’ll even get a 3D preview of the mailer box as it is designed.

To use the online design tool, select “Design Your Mailer Box Online” on the calculator.


What if I want to design it offline?

If you’ve designed your mailer box offline using a tool like Adobe Illustrator, you can place your order and request a PDF dieline template based on these specifications. The dieline will show where the bleed, trim, and crease lines should be on your file so that all details in the artwork are printed correctly.


How can I accurately measure the interior dimensions of the mailer box?

  • Open the box and make sure the interior is facing you while you make the following measurements:
  • The length is measured from the left to right sides of the box.
  • The width is measured from the front to the back sides of the box.
  • The depth is measured from the top to the bottom of the box.

Can I print on both sides of the mailer box?

Yes, you can print on both sides of the mailer box. Under "Printed Sides" on the online calculator, select "Outside & Inside - Full Color".


Request a Custom Quote

Special requests for the dimensions, coatings, and other printing options?
Get a custom quote from a box specialist

Positive Feedback from Positive Experiences.

"I have been using NextDayFlyers for the past 8 years. The quality is excellent. What you submit is what you get. Even better still is the customer service. They will contact you if they see any questionable design flaws. I am not a professional designer, so I appreciate the extra care in them looking out for me."
Doug Samuelson
California
"Really good company to deal with, I've swapped all my offset printing to NextDayFlyers. Would highly recommend."
James Wilson
South Carolina
"You folks never disappoint.! I enjoy seeing my hard work in print. Your attention to detail and promptness in shipping always always amazes me. Thank You!"
Mindy
Arizona