Custom Mailer Box

Make an impression the second your package arrives with custom mailer boxes. Our customizable shipping boxes come in standard and custom sizes and are constructed from sturdy E or B flute cardboard. Brand your mailing boxes with vivid, 4-color print on the inside and outside of your shipping box to vibrantly deliver your brand to customers’s mailboxes.

Choose your size *
Choose your material *
Printing side options *

Instant quote

Get volume discounts and pricing on the spot with all orders.

An eco-friendly choice

Fully recyclable and made from a minimum of 70% recycled material.

Low minimums

Don’t get saddled with unrealistic minimums and exorbitant setup costs of traditional print.

Type Size Apx Volume Templates
Flip-Top Box L4" x W4" x D2" 32 cubic inches Download
Flip-Top Box L6" x W6" x D2" 72 cubic inches Download
Flip-Top Box L8" x W5" x D2" 80 cubic inchs Download
Flip-Top Box L7.5" x W7.5" x D2" 112.5 cubic inches Download
Flip-Top Box L8" x W6" x D4" 192 cubic inches Download
Flip-Top Box L10" x W12" x D2" 240 cubic inches Download


This eco-conscious material not only embraces dark hues with finesse but also exudes a simple yet refined aesthetic, perfect for any packaging needs. With the highest recycled content among materials, Kraft embodies unparalleled eco-friendliness.

Essential White

Our essential white material stands as a timeless and cost-effective choice for crafting custom branded boxes. This standard white board, with a subtle low shine, provides a reliable canvas for showcasing vibrant colors, logos, text, or design elements.

Premium White

Elevate your packaging with our Premium White material, designed to impress at every glance. Crafted from premium board, its smooth texture and luscious gloss make a striking impression. It delivers near photo-quality print that redefines the possibilities on cardboard

Below are some key recommendations to keep in mind when creating your artwork. By adhering to these guidelines, you can ensure optimal print quality and consistency in your designs. Let's dive into the details!

Color Recommendations - Black & Gray

Ensure that black text or linework is set to a CMYK value of 0-0-0-100, utilizing solely black ink rather than a composite or "rich" black value.

For expansive gray sections, it's advisable to employ a CMYK value of 0-0-0-20, devoid of cyan, magenta, or yellow components.

When dealing with extensive black surfaces, like a background, opting for our "rich" black value (CMYK 60-40-40-100) is recommended to mitigate any potential banding issues during printing.

Raster Images

Frequently saved as a .jpg, .png, .psd, .tif, or occasionally a .pdf file format, we advocate for high-resolution images at 300 pixels per inch (ppi). Lower resolutions, below 300 ppi, can lead to visibly reduced print quality when converted to halftone for printing. Opting for high-contrast raster images is advised to achieve optimal print outcomes

Vector Graphics

Typically identified as either an .ai, .eps, and often now a .pdf file format, ensure to outline all text to maintain consistent appearance and prevent unexpected alterations.

For images, embed them to avoid potential printing issues related to unlinked files. Flatten all transparencies, including any screens or overlays with less than 100% opacity, or alternatively, convert them to a 100% opacity CMYK color build. This ensures seamless printing without any transparency-related complications.


Opt for a font size of 10pt (corrugated) or 6pt (paperboard) or larger to ensure clarity and legibility in the final print. Fonts smaller than this may result in fuzzy or indistinct text.

For enhanced legibility, choose thicker or bolder fonts. Reserve the use of script or thin fonts for specific instances, as they may not reproduce well in print and could appear fuzzy or faint.

When utilizing light-colored or knockout-white text on a dark background, prioritize bold or thick-lettered fonts whenever possible. Inks may bleed slightly, and the dark background can create an optical illusion that diminishes the visibility of text, potentially causing it to "disappear." This principle also applies to intricate line art or fine detailing.

Packstudio Custom Printed Packaging

Customizable mailer boxes that fit your brand

Looking to level up your mailing game? Our custom mailer boxes are just what you need, whether you're boosting your in-store sales or conquering the online marketplace. It's all about delivering that perfect package that screams your brand and keeps your products safe on their journey to customers.

With Packstudio, you call the shots. Customize your box with the design, size, and materials that fit your brand, ensuring your packaging stands out in all the right ways.

About Us

Got questions about mailer boxes?

Got questions? We've got answers! Welcome to the FAQ section all about our awesome custom mailer boxes. Whether you're a newbie or a seasoned pro, here's where you'll find everything you need to know about designing, ordering, and rocking your packaging game with Packstudio. Dive in and let's clear up those queries!

Talk To An Expert
What is the difference between a mailer and a shipper box?

A mailer box is a packaging solution designed to securely ship products directly to customers while also serving as an attractive presentation for the product inside. Unlike traditional shipping boxes, mailer boxes are often made of durable materials like corrugated cardboard but feature a more aesthetically pleasing design with custom printing and branding elements.

What are mailer boxes used for?

Mailer boxes are versatile packaging solutions used for various purposes across industries. Primarily, they are employed for shipping products directly to customers in a secure and presentable manner. These boxes are designed to offer both protection during transit and an aesthetically pleasing unboxing experience. Mailer boxes are commonly utilized by e-commerce businesses to package items such as clothing, cosmetics, electronics, and artisanal goods. They serve as a branding tool, allowing businesses to customize the packaging with their logo, colors, and messaging, thereby enhancing brand recognition and customer loyalty. Additionally, mailer boxes are eco-friendly alternatives to traditional packaging materials, often made from recycled or biodegradable materials, aligning with the growing consumer demand for sustainable practices. Overall, mailer boxes streamline the shipping process, elevate brand image, and contribute to a positive customer experience.

How do we ship our mailer boxes?

At Packstudio, we take a unique approach to shipping our mailer boxes: we ship them unfolded. This strategic decision offers several advantages for both us and our customers.

Shipping mailer boxes unfolded optimizes storage space and reduces shipping costs, allowing us to pass on savings to our customers. Upon receiving their order, customers can easily assemble the mailer boxes following simple instructions provided, ensuring a hassle-free packaging experience.

What is the best material for mailer box?

The choice of material for a mailer box depends on various factors, including the nature of the products being shipped, environmental considerations, and branding preferences. However, one of the most popular and versatile materials for mailer boxes is corrugated cardboard.

Corrugated cardboard offers an excellent balance of strength, durability, and lightweight properties, making it ideal for protecting items during transit while minimizing shipping costs. It consists of fluted paperboard sandwiched between two flat linerboards, providing structural integrity and cushioning against impacts.

From an environmental standpoint, corrugated cardboard is highly sustainable, as it's primarily made from recycled materials and is fully recyclable after use. Additionally, it can be easily customized with printing, branding, and design elements to create a unique unboxing experience and enhance brand visibility

Are custom boxes worth it?

Custom boxes offer numerous benefits that make them worth the investment for businesses across various industries. Unlike standard packaging solutions, custom boxes are tailored to meet specific branding, marketing, and product protection needs.

One of the primary advantages of custom boxes is brand differentiation. By incorporating unique designs, colors, logos, and messaging, businesses can stand out in a crowded marketplace and leave a memorable impression on customers. Custom boxes serve as powerful marketing tools, reinforcing brand identity and enhancing brand recognition with every shipment.