Custom Mailer Boxes

Custom mailer boxes are self-locking corrugated shipping boxes built around your exact product, printing, and material specifications — the umbrella category covering every mailer box style, from tuck-top and corrugated builds to kraft, white, and fully printed finishes. They’re the go-to packaging for e-commerce, subscription, and retail brands that want one box to handle branding, protection, and shipping cost all at once. Crat Packaging manufactures custom mailer boxes at its own US facility, with full customization across style, material, and print, free design support, and MOQs starting at 100 units.

Why Choose Our Custom Mailer Boxes

• Every mailer style under one roof — roll end tuck top (RETT), roll end tuck front (RETF), and corrugated builds, so you order the right structure for your product instead of forcing a fit.
• Fully custom dimensions — every box is die-cut to your product’s length, width, and height, cutting wasted space and lowering shipping cost.
• Material and flute choice — kraft or white corrugated liner, in E-flute, B-flute, or C-flute thickness matched to your product’s weight and fragility.
• Full CMYK and PMS printing — unlimited colors at no extra charge, with exact brand-color matching and inside, outside, or both-sides printing.
• Premium finishing available — matte or gloss lamination, spot UV, foil stamping, and embossing/debossing for a retail-grade unboxing moment.
• Self-locking, tape-free assembly — every style closes securely without tape or glue, speeding up pack-out at any volume.
• Recyclable, US-sourced material — fully recyclable corrugated board, produced domestically, with no setup or die-cut charges added.

Specifications

Types of Custom Mailer Boxes

Not every product needs the same box. Roll end tuck top (RETT) is the most common style, with a self-locking front flap that suits subscription boxes, apparel, and small accessories. Roll end tuck front (RETF) adds a front tuck closure for slightly heavier or more delicate products that need a more secure seal. Corrugated mailer boxes, built in single-wall or double-wall board, are the right call for fragile or high-value items that need extra crush resistance. Beyond structure, we also build cosmetic mailer boxes sized with inserts for bottles and jars, subscription mailer boxes designed around a repeatable unboxing experience, and e-commerce mailer boxes optimized for weight and shipping cost.

Customization Options

Style Selection

Tell us your product’s weight, fragility, and how it will be handled in transit, and we’ll recommend the right structure — RETT for most direct-to-consumer shipments, RETF for a tighter seal, or full corrugated construction for fragile or heavier goods.

Materials & Flute Thickness

Kraft corrugated gives a natural, sustainable-looking brown finish; white corrugated gives a clean base for vibrant, true-color printing. E-flute (1/16″) is the standard for lightweight items under roughly two pounds and gives the sharpest print detail. B-flute (1/8″) adds crush resistance for heavier or stacked shipments, and C-flute (3/16″) is the standard structural choice for glass, dairy, or furniture-adjacent shipping.

Printing & Finishing

Full CMYK printing covers the box inside and out at no added color cost, with PMS spot colors available for exact brand-color matching. Add matte or gloss lamination, spot UV on logos, foil stamping, or embossing/debossing for a premium, retail-ready finish.

Add-Ons

Corrugated or foam inserts keep bottles, jars, and multi-item sets centered during transit. Window cutouts let a product show through the box for retail-facing shipments.

Industries & Use Cases

E-commerce and Shopify-based brands use custom mailer boxes as their primary shipping and branding vehicle, since one box handles both jobs at once. Subscription box companies rely on a consistent, repeatable mailer design across every monthly shipment. Apparel and fashion brands use tape-free, fold-flat structures that protect folded garments without snagging fabric, while cosmetics and skincare companies pair mailer boxes with foam or corrugated inserts to protect glass bottles and jars. Electronics and accessories brands use corrugated builds for extra crush resistance, and food and beverage companies (non-perishable items) use custom mailer boxes for gift sets and retail-ready shipments.

How to Order

1. Send us your product dimensions, target quantity, and preferred style (or let us recommend one based on your product).
2. Our design team builds a free dieline and digital proof — a physical sample is available on request.
3. Approve the proof, selecting material, flute thickness, and finishing before production starts.
4. Production runs 10–15 business days standard, or 8 business days with expedited service.
5. Boxes ship flat-packed to keep freight costs down and assemble quickly without tape.

Why Wholesale Buyers Choose Crat Packaging

Crat Packaging manufactures custom mailer boxes at our own US facility, giving us direct control over structure, print quality, and turnaround across every style we offer. There are no setup, plate, or die-cut charges, design support is free from first sketch to final proof, and the minimum order is just 100 units — enough to test a style and size combination before scaling up. Bulk pricing starts from around $0.75 per unit, depending on size, material, quantity, and finishing.

Frequently Asked Questions

What’s the difference between RETT and RETF mailer boxes?

Roll end tuck top (RETT) is the most common mailer style, with a self-locking front flap suited to subscription boxes, apparel, and small accessories. Roll end tuck front (RETF) uses a front tuck closure instead, giving a tighter seal for slightly heavier or more delicate products.

Are they worth it for a small business?

For most direct-to-consumer brands, yes — a mailer box combines shipping protection and branded unboxing in a single purchase, which is usually cheaper than buying a plain shipping carton and a separate branded insert. Our 100-unit minimum also makes it accessible to test before committing to a larger run.

What size custom mailer box do I need?

We size every box to your product’s exact length, width, and height rather than a fixed chart, which keeps shipping costs down and prevents the product from shifting in transit. Share your product dimensions and we’ll confirm the right internal size.

Can I get both inside and outside printing?

Yes. Outside printing covers shelf and shipping impact, while inside printing — on the lid or interior walls — creates a branded reveal the moment the box opens. Both can run in the same full-CMYK print pass.

What’s the minimum order quantity?

Our minimum order is 100 units, with no setup, plate, or die-cut charges added to your quote. Pricing improves at higher volumes.

Do these boxes need tape to close?

No. Every style we build — RETT, RETF, or corrugated — uses a self-locking closure that folds and holds without tape when the box is sized correctly for your product.

Which mailer box style is best for fragile items?

Corrugated mailer boxes, built in single-wall or double-wall board, give the most crush resistance for fragile or high-value items. We can also add corrugated or foam inserts to keep glass, ceramics, or multi-item sets from shifting.

Not sure which mailer box style fits your product? Get a free quote from Crat Packaging today.