Custom Corrugated Mailer Boxes
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Self-locking custom corrugated mailer boxes built for direct-to-consumer shipping, no tape or extra assembly required.
$0.89
UNLIMITED CUSTOMIZATION OPTIONS
A printing technique employing a plate to transfer designs onto paper. Ideal for extensive print jobs.
Plate-free digital printing transfers designs electronically, cost-effective for short runs.
Screen printing is a method using a mesh screen and stencil to transfer ink onto a substrate.
Quick-drying printing technique utilizing ultraviolet lights for ink curing, yielding a glossy finish.
Consisting of water-based pigments, Ensures top-notch color output with a 100% eco-friendly profile.
Fluorescent inks are vibrant, UV-reactive pigments that emit vivid colors under ultraviolet light.
Generate pure colors using specific ink formulas to consistently & precisely reproduce color in printing.
Produce metallic colors through precise ink formulations to replicate color in printing.
Premium bleached white paperboard, specially coated on one side to enhance printing & finishing.
Bleached white paperboard, coated on both sides to achieve superior printing quality and finishes.
Top-notch textured paper, perfect for adding a touch of style when wrapping up durable boxes.
A unique paper material showcasing a shiny or matte metallic laminated surface.
Bleached kraft paper crafted from a blend of new and recycled pulp, coated on both sides for optimal printing.
Kraft paper produced from a combination of new and recycled paper pulp, with coating on both sides for printing purposes.
Kraft paper dyed black, manufactured from a blend of new and recycled pulp, and coated on both sides for printing applications.
Crafted from recycled grey chipboard cardboard, also known as uncoated recycled paperboard, ideal for luxury rigid boxes.
Unique paper material showcasing a holographic laminated surface in either glossy or matte finish.
Grey chipboard, one-sided white cardboard with a smooth, printable surface, ideal for luxury rigid boxes.
Gloss lamination enhances visual appeal by applying a shiny finish, and protecting printed materials.
Matte lamination offers a non-reflective finish, providing elegant appearance to printed materials.
Made with a smooth lamination that feels like touching a peach, can choose between a satin or matte.
A UV coating is applied to a specific area and then cured using ultraviolet light to make it sturdy.
A transparent coating is applied using the CMYK printing technique, and it comes in gloss, satin, or matte.
A fast-drying coating that undergoes curing through ultraviolet light is offered in both gloss and matte.
In a printing method, dies are pressed onto the back of the material to create a raised motif.
A printing technique that involves pressing dies onto the front of the material to create a raised motif.
In foil relief printing, foil is transferred at high temperatures, often employing multiple colors.
Craft a die-cut shape with a plastic film layer, revealing a window to showcase the product inside.
We recommend the ideal material and add-ons like lamination, foiling, embossing UV, etc.
Get Free Design Support with your box 3d Renders or Send Your Design File for Printing.
Upon design approval, we’ll print and conduct quality checks before shipping the boxes to you.
Technical Specifications
| Dimensions | Available in Custom Sizes |
| Printing | CMYK, Pantone Color, Full Color & No Printing |
| Paper Stock | Eco-Friendly Kraft, Corrugated Cardboard & Premium Rigid Stock |
| Coating | Semi-Gloss AQ, Gloss UV, Matte UV & Spot UV |
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
| Custom Options | Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink |
| Proof | Digital Proof, 3D Mock-Up |
| Shipping | Shipped FLAT (Free Shipping Across USA & Canada) |
| Help | For further inquiries and Quotes, contact us or email at sales@cratpackaging.com |
Custom corrugated mailer boxes fold and lock into a ship-ready package without tape, making them the fastest option for e-commerce and subscription brands packing orders by hand.
Custom Corrugated Mailer Boxes Specifications
| Box Style | Self-locking, tab-lock, or fold-over mailer |
| Material | E-flute or B-flute corrugated |
| Assembly | No tape needed, folds into a locked shipper |
| Best For | E-commerce, subscription boxes, direct-to-consumer shipping |
| Print Options | Full-color interior and exterior printing |
| Order Volume / MOQ | No minimum on standard sizes |
| Shipping | Flat-packed, ships nationwide via parcel |
Who Buys Corrugated Mailer Boxes
Direct-to-consumer brands packing their own orders choose corrugated mailer boxes because the self-locking design cuts packing time to seconds per order. No tape gun, no extra void fill for structural support, just fold and ship.
Built for E-Commerce Shipping
A corrugated mailer box replaces both the shipping carton and part of the branding job at once. The outer panel carries your logo through last-mile delivery, and the locking flaps keep the box sealed without extra packing tape. For an even tighter corner-lock seal, see our ear lock mailer boxes.
Eco-Friendly Shipping Material
Corrugated mailers are widely recyclable curbside, which fewer poly mailers can claim. A 2025 McKinsey consumer survey found that over 60% of U.S. consumers pick green packaging when they have the choice, which is why more brands are pairing recyclable board with responsible print processes. That’s a real factor for D2C brands whose customers see the box on their doorstep and form a first impression from it.
Interior Branding Options
Because a mailer box opens flat with visible interior panels, many brands print a second design inside, think thank-you messaging, care instructions, or a QR code, without paying for a second box.
Why Order Custom Corrugated Mailer Boxes From Crat Packaging
- Self-locking design that skips tape entirely for faster packing
- Interior and exterior full-color print in one production run
- No minimum order on standard mailer sizes
- Sized to match common e-commerce SKUs and reduce dim weight
- US-based production for shorter lead times
- Free proof review before your first print run
How to Order
- Send your product dimensions or SKU list
- Choose a mailer size and flute weight
- Approve your interior and exterior print proof
- Place your order and receive flat-packed cartons ready to fold
Frequently Asked Questions
Do corrugated mailer boxes need tape?
No. The self-locking tab design folds and locks into a sealed shipper without tape or glue.
What’s the difference between corrugated mailer boxes and corrugated boxes wholesale?
Mailer boxes are built for direct-to-consumer shipping with a self-locking, no-tape design, while our wholesale corrugated line is priced for bulk warehouse and freight use in a standard RSC style. See our custom corrugated boxes wholesale page for the bulk option.
Can I print on the inside of the mailer box?
Yes. Because the box opens flat, interior panels can carry a second full-color design at no extra tooling cost.
What sizes are available for corrugated mailer boxes?
Standard e-commerce sizes are stocked as templates, and custom dimensions are available to match your exact SKU.
Is there a minimum order quantity?
No minimum on standard mailer sizes, though per-unit pricing improves at higher volumes.
How fast do corrugated mailer boxes ship?
Most orders produce and ship within 10 to 12 business days after proof approval.
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