Die Cut Mailer Boxes
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Die Cut Mailer Boxes give your business the branded materials it needs to leave a lasting impression. Custom design and bulk pricing available on every order. Place your order now and save with wholesale rates!
$0.74
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 |
Die cut mailer boxes go beyond a standard rectangular shipper, using a custom-cut dieline to add windows, handles, locking tabs, or an entirely unique silhouette. Crat Packaging designs and produces custom die cut mailer boxes at our own US facility, with free die-cutting and design support on every order, low minimum order quantities, and no setup or plate charges.
Why Choose Our Die Cut Mailer Boxes
- Fully custom dielines — windows, hang holes, handles, locking tabs, or a unique product-shaped silhouette
- Free die-cutting and plate charges on every order, standard or custom shape
- Compatible with kraft, cardboard, or corrugated stock in any brand color
- Structural engineering support to make sure a custom shape still ships securely
- Full-color printing, lamination, and foil finishing available on any die-cut design
- Free design support from concept sketch to print-ready dieline
- Low MOQ so even complex custom shapes are accessible for smaller brands
Specifications
| Spec | Details |
|---|---|
| Box Style | Custom dieline, including tuck top, tray-and-lid, and windowed styles |
| Material | E-flute/B-flute corrugated board, SBS cardboard, or natural kraft |
| Die-Cut Features | Windows, hang holes, handles, tuck/locking tabs, or a fully custom product silhouette |
| Thickness | 200-350 GSM cardboard or 32ECT-44ECT corrugated |
| Printing | CMYK, Pantone spot color, and full-bleed graphics around die-cut features |
| Finishing | Matte lamination, gloss lamination, spot UV, foil stamping, embossing/debossing |
| Add-ons | Clear PVC or PET window film, custom inserts, tear-notch closures |
| Minimum Order | 100 units |
| Turnaround | 10-15 business days standard, 8 business days expedited |
| Setup/Plate/Die Charges | Free |
Customization Options
Custom Shapes
Our design team builds a dieline around your product, whether that means a simple rectangular window or a fully contoured, product-shaped box.
Windows & Cutouts
Add a clear PVC or PET film window so customers can see the product before opening, a common request for food, beauty, and gift items.
Handles & Locking Tabs
Die-cut handles and tool-free locking tabs make a box easier to carry and close without tape, useful for retail and event packaging.
Materials & Printing
Any die-cut design can be produced in corrugated, cardboard, or kraft stock, with full-color printing and lamination or foil finishing applied around the cut lines.
Structural Testing
We review every custom dieline for structural integrity before production, checking that windows, handles, or cutouts won’t weaken the box during shipping.
Industries & Use Cases
- Food & Beverage: windowed die-cut boxes that let customers see baked goods or products before purchase
- Beauty & Cosmetics: shaped boxes and cutouts that match a specific product silhouette
- Retail & Gift: handle cutouts and display windows for shelf-ready gift packaging
- Subscription Boxes: custom-shaped inserts and cutouts for a distinctive unboxing moment
- Events & Promotional: unique die-cut shapes for branded giveaways and event packaging
How to Order
- Request a free quote with your size, quantity, and finish preferences.
- Our team provides free design support and a proof for your approval.
- Approve the final proof before production begins.
- Production runs 10-15 business days (8 business days for expedited orders).
- Your order ships from our US production facility, ready for your fulfillment operation.
Why Wholesale Buyers Choose Crat Packaging
- Own production facility in the USA, including in-house Mylar bag manufacturing.
- No setup, plate, or die-cut charges on any order.
- Free design support on every custom packaging project.
- Low minimum order quantities so smaller brands can order affordably.
- Bulk pricing starts from around $0.75 per unit, depending on size, material, quantity, and finish.
- Standard 10-15 business day turnaround, with 8-business-day expedited service available.
Frequently Asked Questions
What is a die-cut mailer box?
A die-cut mailer box uses a custom-cut template, or dieline, to add features like windows, handles, or a shape beyond a standard rectangle, rather than a stock box design.
Is there an extra charge for a custom die?
No, Crat Packaging never charges setup, plate, or die-cutting fees, whether you order a standard box or a fully custom die-cut shape.
Can I add a window to see the product inside?
Yes, we die-cut a window opening and apply a clear PVC or PET film so the product is visible without opening the box.
How long does it take to design a custom die-cut shape?
Our design team typically turns around a first dieline concept within a few business days; final production still runs 10-15 business days after proof approval, with an 8-business-day expedited option.
What is the minimum order for die-cut mailer boxes?
The MOQ is 100 units, the same as our standard mailer boxes, even for a fully custom shape.
Will a custom shape still protect my product during shipping?
Yes, every custom dieline is checked for structural strength before production so windows, handles, or cutouts don’t compromise how well the box protects its contents.
Ready to order? Get a free quote from Crat Packaging and our team will send you a proof within one business day.
Shop with Confidence
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