What is a mailer box?

A mailer box is a sturdy corrugated box built for shipping and unboxing, also called a custom mailer box, e-commerce box, or shipping box. It folds flat, locks together without tape, and can be printed inside and out, which is why e-commerce, subscription, and DTC brands use it for a branded unboxing. It ships flat to keep shipping and storage costs down.

What sizes do mailer boxes come in?

You can pick a standard size from the menu, or set a fully custom size to fit your product exactly (measured length x width x height). We fully customize dimensions, so build your exact size in the 3D quote tool and see the price instantly. A snug fit means less wasted space and filler.

Matte or gloss: what lamination can I add to a mailer box?

Both. Matte lamination gives a smooth, low-glare surface, and Gloss gives a shiny, vibrant one. Lamination is a thin film over the print that sets the feel and protects the artwork.

What's the minimum order for custom mailer boxes?

100 boxes. That's low enough for a first launch or market test, with wholesale and bulk pricing as you scale. The unit cost drops at each quantity tier as you build your order.

How much do custom mailer boxes cost?

Price depends on material (White or Kraft Board), size, quantity, printing (outside, inside, or double sided), lamination, finishing, and any custom insert. Larger quantities lower the unit cost, while added printing and finishes raise it. The 3D quote tool updates your landed price live as you build, so there are no surprises.

How long do custom mailer boxes take to make and ship?

Production takes 7 to 12 business days after proof approval. Shipping then depends on your tier: Express is fastest at about a week, with Priority, Standard, and Economy at lower cost and longer transit. Exact timelines show as you build your order.

Can I put food directly inside a mailer box?

No. Mailer boxes are not for direct food contact, so use them as shipping or outer packaging around a product in its own primary pack. If your product touches the packaging directly, use our flexible packaging (pouches) to hold the food, then a mailer box to ship it.

What finishing effects can I add, like foil or Spot UV?

You can add Hot Foil for a metallic shine, Spot UV for glossy highlights on areas like your logo, and Emboss for a raised, tactile effect. These finishing touches sit on top of your print for a premium look.

Custom Mailer Boxes for Ecommerce

Custom Mailer Boxes

Unboxing that earns the second order, built for DTC and subscription brands. From 100 units with an instant proof and a custom sample in 15 days.

Design My Box Now

Custom Mailer Boxes

Unboxing that earns the second order, built for DTC and subscription brands. From 100 units with an instant proof and a custom sample in 15 days.

Design My Box Now

Pink mailer box with skincare products inside

Green mailer box with supplement bottles inside

Close-up of kraft mailer box corner and print detail

Close-up of corrugated mailer box board flute

From 100 Units

Sustainable Options

Instant Quotes

3D Design Preview

Build Your Box. See Your Landed Price.

Select your specs to get an instant landed price.

Size

Need a custom size? Open the designer →

Quantity

Need a different quantity? Open the designer →

Material

Recyclability

Printing

Shipping Method

Production Time

8 - 10 days

Shipping Time

21 - 28 days

Total Fulfillment Time

29 - 38 days

Estimated Delivery

Sep 29 - Oct 8

How It Works?

Design in 3D

Customize and watch it come to life in a live 3D preview.

See Your Landed Cost

Your all-in landed price updates instantly as you build.

Approve Every Detail

Review your proof and sign off before production.

Order a Sample

Hold the real thing first, made on the production line.

Place Your Order

Confirm, and we move straight to production.

Best for

Ships flat, folds into a sturdy box. Built for the unboxing moment, not for direct food contact.

Ecommerce

Subscription

DTC

Gifting

Apparel

Material Options

Compare construction, durability, and recyclability across our White and Kraft options.

Which Material Is Right for You

Not sure where to start? Think about what matters most: print quality, durability, or recyclability. The table compares your three options.

Best for:Premium retailVivid artworkDurability

Lamination:Laminated film

Finishes:Matte / Gloss / Soft Touch

Color:WhiteMulti-color

Durability:★★★★

Water resistant:Yes

Splash resistant:Yes

End of life:Check locally

Structure:SBS / E-flute / SBS

White · Classic

White · Recyclable

Kraft

Best for

Premium retailVivid artworkDurability

Recyclable retailEco-forwardEveryday

Natural brandsOrganicRaw look

Lamination

Laminated film

Uncoated

Finishes

Matte / Gloss / Soft Touch

Matte / Gloss

Color

WhiteMulti-color

Kraft

Durability

Water resistant

Splash resistant

End of life

Check locally

Widely recyclable

Structure

SBS / E-flute / SBS

Kraft / E-flute / Kraft

Recyclability follows How2Recycle and FTC Green Guides: uncoated and varnished board is widely recyclable when clean and dry, while plastic-film-laminated board carries a Check Locally label. Foil, metallization, soft-touch lamination, plastic windows, and heavy specialty coatings can reduce or complicate paper recycling.

Food Safety & Compliance

Recommended as secondary or outer retail packaging, not for direct food contact. For products that touch food directly, we recommend our flexible packaging line, like stand-up pouches and flat pouches, built for food contact. Reach out to our team if you are not sure which fits.

Quality You Can Count On

Why a Dylign box is reliable, order after order.

Color You Can Count On

Offset printing with Pantone-accurate color and sharp, clean text.

Built to Hold Its Shape

Clean folds and solid corners keep every piece sharp and sturdy.

Consistent, run after run

Your tenth reorder looks like your first, from a 100-unit test run to full production.

Nothing Ships Until It's Right

Every order is inspected against your approved specs before it leaves.

Why Choose Dylign?