- sales@apexiopackaging.com
- +1 (123) 456-2026
Our streamlined six-step process ensures your custom packaging vision becomes reality — with precision, quality, and speed.
Share your vision, dimensions, materials & quantities — we listen and plan.
Our designers craft stunning visuals that match your brand identity perfectly.
Preview your product in realistic 3D before going to print — every angle covered.
Once you're happy, approve the final proof and we prepare for production.
State-of-the-art printing & finishing in our quality-controlled factory floor.
Fast, safe worldwide shipping — your packaging arrives ready to impress.
Custom mailer boxes protect what you ship, brand every delivery and turn a plain parcel into an unboxing customers want to share.
A great product can still arrive looking generic in a plain brown shipper, and the mailer is the first thing your customer touches. At Apexio Packaging, we manufacture custom mailer boxes in the USA for e-commerce, subscription, DTC and retail brands. With zero MOQ, free design, a free 3D mockup and free US shipping, you can order one sample or tens of thousands and get the same shipping-grade build every time.
Get your free quote and free 3D design proof today – email sales@apexiopackaging.com or call +1 (855) 466-6990.
Mailer boxes are printed corrugated shipping boxes that fold flat, lock without tape and present your brand on arrival.
A mailer box is die-cut from one sheet of corrugated board, so it ships flat, folds up in seconds and closes with an integrated tuck or lock flap instead of tape. The corrugated wall absorbs shocks, the interior can be printed for the reveal, and the exterior carries your brand. Unlike a fragile folding carton, it is engineered for the parcel network, which is why it is the default for branded e-commerce shipping.
Mailer boxes suit any brand that ships a product, from first-order e-commerce sellers to national retail programs.
E-commerce and DTC brands use mailer boxes to replace plain shippers and make delivery feel intentional. Subscription companies rely on them for a repeatable monthly unboxing, apparel and cosmetics labels protect and present goods, and retail brands order bulk runs for wholesale. Emerging sellers use our zero-MOQ policy to test one design first, and many start with our custom printed mailer boxes.
The right mailer style depends on how the box opens, how it locks and how premium the reveal needs to feel.
| Mailer style | Best for | Why it works |
|---|---|---|
| Roll-end tuck front (RETF) | E-commerce and subscription boxes | Strong double-wall front, easy tuck close, no tape |
| Self-locking mailer | High-volume shipping | Locks flat without glue, fast assembly |
| Front-tuck mailer | Lightweight retail items | Clean face panel, simple and economical |
| Die-cut mailer | Branded gifting and PR kits | Custom shape and print surface, premium reveal |
| Literature / book-wrap mailer | Flat goods, apparel, print | Wraps snug to thickness, low DIM weight |
Choose the structure first, then layer size, board strength, print and finish. Most branded stores start with a roll-end tuck front, while die-cut mailers suit gifting; compare builds in our custom corrugated mailer boxes.
Mailer boxes are cut to any product, and the chart below shows the most requested shipping sizes in inches.
| Box size (L x W x H) | Fits | Common use |
|---|---|---|
| 4 x 4 x 2 in | Jewelry, small accessories, samples | Small e-commerce orders |
| 6 x 4 x 2 in | Cosmetics, candles, small goods | DTC beauty and gifts |
| 8 x 6 x 2 in | Apparel, books, flat goods | Fashion and print |
| 9 x 6 x 3 in | Multi-item monthly boxes | Subscription programs |
| 10 x 8 x 3 in | Apparel sets, mid-size kits | Retail and PR kits |
| 12 x 9 x 4 in | Bulky or multi-product orders | Larger e-commerce shipments |
These are starting points, not limits. We size every mailer to the exact product so it sits snug, which stops movement in transit and keeps the box right-sized to lower dimensional (DIM) weight. Fully bespoke dimensions are cut on request.
Mailer boxes are built from corrugated board and kraft liner, chosen by product weight, stacking load and shipping distance.
| Board / flute | Thickness | Typical ECT | Best for |
|---|---|---|---|
| E-flute corrugated | ~1.5 mm (1/16 in) | ~32 ECT | Lightweight retail items up to 2 lb |
| B-flute corrugated | ~3 mm (1/8 in) | ~40-44 ECT | Standard e-commerce, 2-5 lb |
| C-flute corrugated | ~4 mm (3/16 in) | ~44 ECT | Larger or slightly heavier goods |
| Double-wall (BC-flute) | ~6-7 mm | ~48-51 ECT | Heavy or multi-item kits up to 15 lb |
| Kraft corrugated liner | Brown or white face | – | Natural eco look and clean print base |
Edge Crush Test (ECT) measures how much stacking pressure the board withstands, so heavier products and longer routes call for a higher ECT. E-flute prints sharply for light goods, B-flute is the e-commerce workhorse, and double-wall protects heavy kits. Kraft liner gives a natural, recyclable finish, and we stock FSC-certified board across every flute. We do not build mailers from thin greyboard or single-ply cardstock, because only corrugated survives the parcel network.
We print mailer boxes by three methods, chosen by run size, artwork detail and budget.
| Printing method | Best for | Main strength |
|---|---|---|
| Digital printing | Short runs, samples, fast launches | No plates, full colour, quick turnaround |
| Offset (litho-lamination) | Photographic art, premium retail | Sharpest detail, laminated to corrugated |
| Flexographic printing | Large-volume kraft and corrugated runs | Cost-effective direct print, strong spot colour |
Digital printing skips plates, so a single test box or short seasonal batch stays fast and affordable. Offset litho-lamination prints photographic artwork on a liner bonded to the corrugated for a premium finish, and flexography prints directly onto kraft or corrugated for the best value on very large runs.
Mailer boxes print in CMYK and match exact Pantone (PMS) brand colours, while RGB stays for on-screen design.
| Colour system | Use it for | Note |
|---|---|---|
| CMYK | Full-colour art, gradients, photos | Standard four-colour process print |
| PMS (Pantone) | Exact logo and brand colours | Identical shade on every reprint |
| RGB | On-screen design and previews | Convert to CMYK before printing |
CMYK reproduces full-colour artwork, while Pantone (PMS) matching locks a signature brand colour so every reorder stays consistent. RGB is screen-only, so we convert files and confirm on your proof. Our CMYK, PMS and RGB colour guide explains it in plain terms.
Finishes make a mailer box feel premium and add durability, and most pair one base coating with one or two accents.
| Finish | Effect | Best for |
|---|---|---|
| Matte / gloss lamination | Sets the base surface feel | Printed retail and DTC mailers |
| Soft-touch coating | Velvety premium hand-feel | Beauty and luxury brands |
| Spot UV | Glossy accent on a matte base | Logos and highlights |
| Foil stamping (gold, silver, holographic) | Metallic shine | Gifting and PR kits |
| Embossing / debossing | Raised or recessed texture | Tactile, high-end branding |
| Water-based aqueous coating | Scuff resistance for transit | Kraft and eco mailers |
Lamination sets the base feel and protects print from scuffing, while soft-touch, foil, spot UV and embossing add a premium accent.
Ready to build yours? Get a free quote and a free 3D proof now – email sales@apexiopackaging.com or call +1 (855) 466-6990.
Inserts and add-ons hold the product in place and turn the mailer into a complete, protected unboxing.
| Insert / add-on | What it does | Best for |
|---|---|---|
| Die-cut foam (EPE / EVA) | Firm shock protection | Fragile, glass and electronics |
| Corrugated dividers / partitions | Separates multiple items | Multi-product and kit orders |
| Tear-strip / zipper opening | Easy, tool-free open | Subscription and DTC unboxing |
| Inside printing | Branded interior reveal | Every branded shipment |
| Molded pulp tray | Recyclable fitted hold | Eco-conscious brands |
A foam or corrugated insert gives each item a planned position so nothing shifts in transit, a tear-strip makes the box effortless to open, and inside printing turns the lid into a branded moment. Delicate goods pair well with our custom jewelry mailer boxes.
Mailer boxes are engineered for the parcel network, so they protect products, cut waste and lift the unboxing.
A right-sized mailer does three jobs at once: the corrugated wall protects against drops and stacking, the snug fit removes rattle and cuts damage claims, and the tight dimensions lower dimensional (DIM) weight so you pay less to ship. A printed interior and clean lock flap make delivery feel considered, which drives repeat orders and social shares. For a coordinated brand experience, pair mailers with our custom printed bags.
We produce and ship mailer boxes free to e-commerce and retail brands nationwide.
Apexio Packaging serves brands in California, Texas, Florida, New York and Illinois, plus Los Angeles, Chicago, Miami, Seattle and Denver, and ships free to every state. A LA apparel brand may choose printed B-flute mailers, while a Texas subscription brand may need double-wall boxes with dividers.
Ordering wholesale mailer boxes stays simple, with zero MOQ, free design and free US shipping.
Order a single sample to test artwork, or a large run for a wholesale program. Standard production runs about 5-7 business days after proof approval, with a RUSH option. We also create 3D mockups and dielines so you review everything before printing, and per-unit pricing drops sharply at 100 units or more.
Order now with zero MOQ and free US shipping – get your free quote today.
We review every mailer for board strength, fit, print and fold before it ships, and we are honest about what corrugated can and cannot do.
We check flute alignment, ECT rating, print registration, colour accuracy and score strength, and we confirm the box holds up to courier handling and stacking. For heavier or fragile shipments we validate the build against ASTM D4169 distribution testing. Corrugated is tough and recyclable, but it is not a rigid gift box, so if you need a luxury reusable structure we will say so honestly and point you to the better option.
Your product deserves packaging that protects it and sells your brand at the doorstep. Start with zero risk: no minimums, free design, a free 3D mockup and free US shipping on every order. Send us your product size and brand, and we turn it into printed mailer boxes that survive transit, cut shipping waste and earn the unboxing. Get your free quote and free design proof now – email sales@apexiopackaging.com or call +1 (855) 466-6990.
