Custom Corrugated Mailers

Mailer boxes are typically designed for retail presentation and branding in addition to protection, often featuring printed graphics and a more finished appearance for unboxing experiences. Shipping boxes (like standard corrugated cartons) prioritize protection and cost efficiency for bulk transit, with less emphasis on aesthetics. Many e-commerce brands use mailer boxes to combine shipping durability with brand presentation.

Custom corrugated mailers are commonly available in E and B flute corrugated board, which provide a good balance of durability and print quality for lightweight to moderate shipping needs. Flute selection affects the mailer's rigidity, cushioning, and overall thickness, and should be chosen based on product weight and fragility.

Custom corrugated mailers can be produced using digital print or flexographic (flexo) print. Digital printing allows for photo-quality graphics without color penalties or the need for print plates, making it ideal for smaller runs. Flexo printing is typically more cost-effective at higher volumes but may require plate setup.

No minimum order quantity is required for digitally printed corrugated mailers, making them accessible for brands ordering anywhere from a single unit up to 5,000 units. Larger orders may be better suited to flexo printing, which becomes more cost-effective at scale.

Yes, custom corrugated mailers can be designed with optional interior branding, custom corrugated or folding carton inserts, and a mailer return feature for added protection. These options help create a more elevated unboxing experience while providing extra product security during shipping.

Same-day digital quotes are available for orders between 1 and 5,000 units using E and B flute corrugated board. Pricing varies based on size, quantity, and chosen print method, so providing detailed specifications upfront helps speed up the quoting process.