Folding Mailer Boxes
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Custom folding mailer boxes with interlocking, tape-free closures and interior/exterior print for e-commerce brands.
$0.90
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 |
Folding mailer boxes combine flat-shipped efficiency with shipping-grade durability, giving e-commerce brands a carton that doubles as both a retail box and a direct-to-consumer mailer. Crat Packaging builds each mailer to your exact product dimensions, with interlocking flaps that skip the tape gun entirely.
Folding Mailer Boxes Specifications
| Box Style | Self-locking, tuck-top, and interlocking flap mailer styles |
|---|---|
| Material | E-flute or B-flute corrugated, or heavy SBS paperboard |
| Assembly | Ships flat; folds and locks by hand, no tape required |
| Best For | E-commerce, subscription boxes, direct-to-consumer shipping |
| Print Options | Full-color CMYK exterior and interior, matte lamination |
| Order Volume/MOQ | Custom runs from as low as 100 units |
| Shipping | Flat-packed for low freight cost, shipped nationwide |
Built for Both Retail and Shipping
Unlike a standard folding carton meant only for shelf display, a mailer box is engineered to survive the parcel network on its own, without an outer shipping case. Reinforced corners and interlocking flaps keep contents secure through sortation and last-mile delivery.
Who Orders This Format
Subscription box companies, apparel brands, and direct-to-consumer product lines use folding mailer boxes to cut packaging steps and create an unboxing moment that starts the instant a customer opens their front door, not just when they open an inner box.
Branded Interior and Exterior Printing
Because the mailer is the first thing a customer sees, we print full color on both the exterior shipping surface and the interior lid, so your branding carries through from doorstep to unboxing without a second package layer.
Eco-Friendly Shipping Packaging
A 2025 McKinsey survey found that over 60% of U.S. consumers pick green packaging when they have the choice. Our recyclable corrugated and paperboard options cut down on single-use shipping materials compared to a box-in-a-box setup.
Related Mailer Packaging
For a lighter-weight, poly-based option, see our Custom Poly Mailers page. For budget-focused corrugated mailers, see Affordable Mailer Boxes. For general folding-carton basics, see Folding Boxes.
Why Order From Crat Packaging
- Interlocking, tape-free mailer construction
- Interior and exterior branding on the same box
- Low minimums for growing e-commerce brands
- U.S.-based production for faster turnaround
- Recyclable corrugated and paperboard options
- Free samples before your full production run
How to Order
- Send your product dimensions and target quantity
- Approve a free digital proof and structural dieline
- Review a physical sample before full production
- We print, finish, and ship flat-packed mailers to you
Frequently Asked Questions
Do these boxes need tape to seal?
No, interlocking flaps and self-locking closures hold the box shut without tape or extra sealing materials.
Are folding mailer boxes durable enough for shipping alone?
Yes, we build them from corrugated or heavy paperboard engineered to survive the parcel network without an outer case.
How is this different from Custom Poly Mailers?
Poly mailers are flexible plastic pouches. Folding mailer boxes are rigid cartons better suited to fragile or boxed products.
Can you print on the inside of the box?
Yes, interior lid printing is a standard option for an unboxing moment that matches your exterior branding.
What is the minimum order quantity?
Custom runs start at low minimums, practical for growing e-commerce and subscription brands.
How long does production take?
Turnaround runs from design approval to shipment, with rush options available for time-sensitive launches.
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