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Custom Size Mailer Boxes

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Give your items the perfect fit with our custom size mailer boxes, primarily designed to match your exact needs. We create strong as well as stylish boxes that protect items during shipping and also give your brand a clean and professional look. Select any custom size, color, & finish to make your mailer packaging boxes stand out.

We at PackagingBee offer high-end printing, free design support, quick delivery, & budget-friendly pricing for every order. Our professional team works with you to make sure your product packaging looks great.

So, don't wait & create a unique unboxing experience for your customers as well as leave a lasting impression. Place your order today & take your packaging to the next level!

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GET INSTANT QUOTE OF PRODUCT BOXES

retail fast & reliable packaging service

  • Starting From 100 Boxes
  • High Quality Offset Printing
  • Custom Sizes & Style
  • 8-10 Business Day Turnaround
  • Free Shipping
  • Recyclable

What are Custom Size Mailer Boxes?

Custom size mailer boxes are packaging boxes made to fit your product dimensions exactly. You select the length, width, and height based on your item. This really helps you avoid extra space as well as keeps products secure during shipping. These boxes use strong cardboard or corrugated packaging material for better protection. Businesses use them for e-commerce, retail, & subscription packaging. In addition, mailer boxes also support branding. You can print logos, colors, and product details on the box. This improves brand identity and customer experience. A perfect fit minimizes damage risk and lowers shipping costs. These boxes help you deliver products safely while giving a professional look.

Must-Have Features of Custom-Size Mailing Boxes

Custom size mailing boxes give a smart packaging solution for your products and make sure they fit perfectly. They are an excellent option for improving product protection, branding, and shipping. The features of these boxes include;

A Perfect Product Fit

These mailer boxes with inserts are made exactly to the specifications of your product's dimensions. As there will be no space inside, the items are secure during transit, and reduce movement, which lowers the risk of damage.

Robust Material Construction

Cardboard and corrugated materials used in mailer boxes are robust and add extra protection for your products during shipping. Strong construction prevents damage to your products and adds robustness in storage and transit requirements.

Cost-Effective for Shipping

Less wasted space in the mailer boxes reduces shipping costs and saves packaging material. Businesses achieve higher packing efficiency. They most commonly offer a cost-effective solution in terms of shipping as well as product packaging.

Promote Brand Identity with Customization

Customize boxes with your company logo, name, and any other relevant product details. This enhances the brand identity and visibility during delivery and while unboxing by customers.

Simple to Use Design

Mailer boxes feature simple folding and tuck-in designs, which make packaging quick and easy. This will help save time and manpower while packing orders. They ensure a neat and secure packing experience!

Mailer Box Sizes That Match Your Every Product

Mailer box sizes are completely adjustable to perfectly suit your product and order. All you need to do is select the desired length, width, and height, depending on your item size, as well as the requirements for shipping. Standard mailing box sizes (in inches):
  • 6 x 4 x 2 (ideal for accessories and small items)
  • 8 x 6 x 2 (suitable for cosmetics and small kits)
  • 9 x 6 x 3 (good for light retail products)
  • 10 x 8 x 4 (ideal for apparel and bundles)
  • 12 x 9 x 4 (excellent for medium e-commerce items)
  • 14 x 10 x 5 (perfect for bulk or multi-product packages)
  • 16 x 12 x 6 (good for larger products and subscription boxes)
It's possible to go completely custom if the available options aren't suitable for you, and it may look something like this:
  1. Mini size for samples
  2. Slim size for thin, flat items
  3. Deep size for bulky items
Ensuring your mailer box fits perfectly to minimize shipping costs. This ensures adequate protection and offers an enjoyable unboxing experience for the customer.

Strong Material Choices For Reliable Custom Design Mailer Boxes

A strong and reliable material for custom design mailer boxes is crucial for Mailer boxes in order to keep the products safe while they're being delivered. The accurate material can increase the safety, branding, and performance of the packaging for your brand. Here are some of the top material options we offer;

Corrugated Cardboard

Corrugated cardboard offers strong protection for deliveries. This material can withstand pressure, weight, and rough handling. Brands opt for this when producing e-commerce and mass product boxes as it will keep the products safe during lengthy journeys, minimizing damage.

Kraft Paperboard

Kraft paperboard can be a good, sustainable, and natural choice. This is ideal for brands that want an environmentally friendly brand image and for use with lighter products. Kraft is also reasonably strong and able to be printed on easily for simple logos and designs.

Rigid Board

Rigid board is great for creating premium custom mailer boxes no minimum. It would suit high-end products and luxury packaging, for example, for gift boxes and deluxe items. It can improve the unboxing experience as it provides a high-quality and brand-enhancing experience.

Recycled Paper Material

Recycled paper material helps with meeting environmentally conscious packaging demands, reduces the level of waste, and resource depletion.

High-Quality Printing Options For Mailer Boxes

Printing makes the mailer boxes appealing and professional. There are varying outputs based on design requirements, order quantity, and budget, depending on the chosen printing process.

Offset Printing

You can get high-definition print and accuracy for large volumes. It produces detailed print with crisp color and precise details, commonly used by brands for large order packaging due to cost-effectiveness in larger volumes, and consistent quality on each box.

Digital Printing

With Digital Printing, you get excellent quality for smaller quantities; it's faster to set up and faster to print, which brands prefer when ordering custom, short runs with design variations, as this requires no set-up fee.

Flexography Printing

Suitable for high-volume packaging that demands faster print speeds. It requires less ink, and is easy to adjust the ink and print without the concern for a setback due to the quick changeovers between different designs and substrates, such as corrugated cardboard or kraft paper.

Why Invest In Packaging Bee’s Mailer Boxes?

We make your brand look professional and ship products safely. We create sturdy custom size mailer boxes that complement your products, enhance your unboxing experience, and allow you full customization in size, color, style, and printing to enhance your brand identity. Plus, we use high-quality materials that keep your items safe during shipping as well as ensure high-quality printing, free design assistance, rapid production, & reasonable prices for any order volume. We value quality along with customer satisfaction in every order. Order custom mailer boxes today!
Dimensions All Custom Sizes & Shapes
Printing CMYK, PMS, No Printing
Paper Stock 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock
Quantities 100 - 500,000
Coating Gloss, Matte, Spot UV
Default Process Die Cutting, Gluing, Scoring, Perforating
Options Custom window cut out, gold/silver foiling, embossed ink, raised ink, and PVC sheet.
Proof Flat View, 3D Mock-up, Physical Sampling (On request)
Turn Around Time 4-6 Business Days, Rush

  • How Should I Select Custom Size Mailer Boxes?

    Take your product's dimensions and add enough buffer for fitting it well within the package and easy movement while packaging.

  • Do Custom Mailer Boxes Have Potential For Branding?

    Branding elements, including the business logo, brand name, and colors, can be added to the mailer boxes to make your brand recognizable.

  • Are Custom Size Mailer Boxes Sustainable?

    Mailer boxes are primarily available in recycled material as well as Kraft paper.

  • Which Businesses Should Opt For Mailer Boxes Sizes?

    They can be used for e-commerce businesses, brands that sell clothing, cosmetic products, and subscription boxes.
Printing Options
Material
Special Finishes
Coating and Lamination
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Offset Print

High-quality and low-cost printing option that transfers the image to the box surface in a good resolution.


Digital Print

Digital printing techniques do not require any sort of printing plate as it transfers the image to the surface of the box easily without a plate.

UV Print

Safeguard the printed area from fading and make them more attractive.



Pantone

Utilization of a universally accepted color-matching system for printing the boxes.

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Corrugated

A fluted box material is created to enhance the strength of the boxes for shipment purposes.

Cardboard

Light in weight and easy to print cardstock material that would be molded into any shape and style.

Kraft

Slightly brown paper-like thin material for packaging created by wood pulp and heaving eco-friendly nature.

Rigid

A thick cardboard box that is high in strength but also luxurious in presentation.

Holographic

An impressive as well as laminated paperboard that emulates a 3d look to colors.

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Hot Foil Stamping

Print the foil detail by using the hot dies on the surface of the packaging boxes.

Cold Foil Stamping

It is a removable foil stamp that is applied without pressing any hot die or pressure on the boxes.

Blind Embossing

Create the raised area on the box surface by applying the pressure, not the inks.

Blind Debossing

Just like the craving on the box created by using letter plates or letter presses.


Registered Embossing

Create both the texture as well as the depth and endow a 3d effect to the area of the box.

Combination Embossing

Both the design as well as foiling is utilised at the same time to create a more appealing presentation.

Window Patching

Create a plain see-through cut in the box that is covered with a see-through plastic sheet.

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Aqueous Coating

Provide tear-free impact to the packaging with a clear and fast-drying water-based coating at the time of printing.

UV Coating

Add protection against the damaging impact of UV sun rays by applying the UV coating to the packaging.


Spot Gloss UV

Annex the glossy effect on the specific areas of the packaging through spot coating.


Soft Touch Coating

Use the soft touch coating to make the darker and dull areas of the packaging velvety and smooth.


Varnish

Provides protection as well as perfect presentation to the printing part of boxes.


Lamination

A very thin plastic film is pasted in the boxes to make them more durable and long-lasting.


Anti-Scratch Lamination

This thin film of plastic is used to endow the scuff as well as scratch resistance to the boxes.


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OUR 5-STEP ORDER PROCESS

  • Order

    You can place the custom order directly through our website.

  • Design

    Please choose from our portfolio of custom designs or provide a certain layout, pattern, logo, or artwork.

  • Approve

    You will get an email as a confirmation once you finalise the custom design.

  • Production

    Our team will develop the custom boxes tailor-made to your exclusive designs

  • Delivery

    You will get the order delivered within two weeks after your confirmation

Have More Queries?

To know more about our order process, 24/7 customer support is available to handle all your queries & concerns related to:

  • Delivery Time

  • Customisation

  • Order Size

  • Price Comparison

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+1 (503) 381-6437
EMAIL
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ADDRESS
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