Custom corrugated mailer boxes in E-flute, B-flute & double-wall with tested ECT strength. USA-made, zero MOQ & free shipping. Get a free quote today!










Six simple steps stand between your idea and stunning custom packaging landing at your doorstep. No guesswork, no stress — just results.
Custom corrugated mailer boxes pair tested board strength with tape-free assembly and full-color branding, so products arrive safe and on-brand.
Shipping damage costs sales and trust, and the corrugated wall is what stands between your product and a rough courier network. At Apexio Packaging, we make custom corrugated mailer boxes in the USA in E-flute, B-flute and double-wall builds. With zero MOQ, free design, a free 3D mockup and free US shipping, you can order one sample or a full run at the same tested quality.
Get your free quote and free 3D design proof today – email sales@apexiopackaging.com.
A corrugated mailer box is a die-cut shipping box with a fluted inner layer that cushions the product in transit.
The wavy flute between two liners gives corrugated its strength-to-weight advantage, absorbing shocks and resisting crushing. The box folds flat, locks without tape and carries print on both faces, which is why it is the standard for e-commerce shipping.
Corrugated mailers suit any brand shipping products that need protection, from light retail to heavy kits.
E-commerce and subscription brands use them daily, apparel and cosmetics labels protect goods in transit, and electronics or multi-item kits use heavier double-wall builds. Eco-minded brands often choose kraft liners, as in our custom kraft mailer boxes.
The right corrugated style depends on weight, closure and how the box opens.
| Mailer style | Best for | Why it works |
|---|---|---|
| Roll-end tuck front (RETF) | E-commerce and subscriptions | Double-wall front, tape-free close |
| Self-locking mailer | High-volume shipping | Locks flat without glue |
| Front-tuck mailer | Light retail items | Simple, economical |
| Die-cut mailer | Branded gifting | Custom shape and print |
| Full-overlap shipper | Heavy or fragile goods | Extra bottom strength |
Most stores start with a roll-end tuck front, while heavy goods use a full-overlap base. For a bold dark finish, compare our custom black mailer boxes.
Corrugated mailers are cut to any product, and the chart shows common shipping sizes in inches.
| Box size (L x W x H) | Fits | Common use |
|---|---|---|
| 6 x 4 x 2 in | Small goods, cosmetics | DTC orders |
| 8 x 6 x 2 in | Apparel, books | Fashion and print |
| 9 x 6 x 3 in | Multi-item boxes | Subscriptions |
| 10 x 8 x 3 in | Apparel sets, kits | Retail and PR |
| 12 x 9 x 4 in | Bulky or multi-product | Larger shipments |
| 14 x 10 x 4 in | Heavy multi-item kits | Wholesale bundles |
We size each corrugated mailer to the product so it sits snug, which stops movement in transit and keeps dimensional (DIM) weight low. Fully bespoke dimensions are cut on request.
Board and flute are chosen by product weight, stacking load and shipping distance.
| Board / flute | Thickness | Typical ECT | Best for |
|---|---|---|---|
| E-flute | ~1.5 mm (1/16 in) | ~32 ECT | Light retail items up to 2 lb |
| B-flute | ~3 mm (1/8 in) | ~40-44 ECT | Standard e-commerce, 2-5 lb |
| C-flute | ~4 mm (3/16 in) | ~44 ECT | Larger, slightly heavier goods |
| Double-wall (BC) | ~6-7 mm | ~48-51 ECT | Heavy or multi-item kits up to 15 lb |
Edge Crush Test (ECT) measures stacking strength, so heavier products and longer routes call for a higher ECT. Kraft or white liners are available, along with FSC-certified stock. We do not build mailers from thin greyboard or cardstock, because only corrugated protects in transit.
We print corrugated mailers by three methods, chosen by run size and artwork.
| Printing method | Best for | Main strength |
|---|---|---|
| Digital | Short runs and samples | No plates, fast and full color |
| Offset (litho-lam) | Photographic, premium retail | Sharpest detail on a bonded liner |
| Flexographic | Large kraft/corrugated runs | Best value, strong spot color |
Digital suits short runs, offset litho-lamination gives photographic quality, and flexo prints directly onto corrugated for the best value at volume.
| Color system | Use it for | Note |
|---|---|---|
| CMYK | Full-color art, gradients, photos | Standard four-color process print |
| PMS (Pantone) | Exact logo and brand colors | Identical shade on every reprint |
| RGB | On-screen design and previews | Convert to CMYK before printing |
Artwork is built in CMYK, with Pantone (PMS) matching for exact brand colors and RGB reserved for screens. Our CMYK, PMS and RGB color guide explains it in plain terms.
Finishes add durability and shelf appeal to a corrugated mailer.
| Finish | Effect | Best for |
|---|---|---|
| Matte / gloss lamination | Base surface feel and scuff resistance | Printed retail mailers |
| Water-based aqueous coating | Light protection, recyclable | Kraft and eco builds |
| Spot UV | Glossy accent | Logos and highlights |
| Foil / embossing | Premium accent | Gifting and PR kits |
Lamination protects print from transit scuffs, while a water-based coating keeps kraft builds recyclable. Foil and embossing add a premium accent where needed.
Ready to build yours? Get a free quote and a free 3D proof now – email sales@apexiopackaging.com.
Inserts hold products in place and complete a protected unboxing.
| Insert / add-on | What it does | Best for |
|---|---|---|
| Corrugated dividers / partitions | Separates multiple items | Multi-product kits |
| Die-cut foam (EPE / EVA) | Firm shock protection | Fragile and glass goods |
| Molded pulp tray | Recyclable fitted hold | Eco-conscious brands |
| Tear-strip opening | Easy, tool-free open | Subscription unboxing |
Dividers organize multi-item shipments, foam protects fragile goods, and a tear-strip makes opening easy. For small luxury goods, see our custom jewelry mailer boxes.
Corrugated mailers are engineered for the parcel network, protecting goods while cutting waste.
A right-sized corrugated mailer protects against drops and stacking, removes rattle and lowers dimensional weight, so you cut both damage claims and shipping cost. On arrival the printed box lifts the unboxing. Explore every structure on our custom mailer boxes hub.
Ordering corrugated mailers stays simple, with zero MOQ, free design and free US shipping.
Order a single sample or a large wholesale run. Standard production runs about 8-12 business days after proof approval, with a RUSH option. For premium reusable builds, compare our custom rigid boxes.
Order now with zero MOQ and free US shipping – get your free quote today.
We check every corrugated mailer for board strength, fit, print and fold before it ships.
We confirm flute alignment, ECT rating, print registration and score strength, and for heavier or fragile shipments we validate the build against ASTM D4169 distribution testing. Corrugated is tough and recyclable, but if you need a rigid gift box we will say so honestly.
Helpful reading: our guide to how to read box dimensions.
Protect your products and brand every delivery. Start with zero risk: no minimums, free design, a free 3D mockup and free US shipping. Send us your product and weight, and we turn it into custom corrugated mailer boxes tested for transit. Get your free quote now – email sales@apexiopackaging.com.
| Box Style | Custom Corrugated Mailer Boxes |
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Quantities | No Minimum Order Required |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 8-12 Business Days, RUSH |
| Shipping | FLAT |

14pt cardstock is a lightweight yet sturdy paperboard commonly used for product packaging, postcards, and promotional prints that require flexibility with reliable durability.

16pt cardstock offers a thicker, more durable structure than standard paperboard, making it ideal for business cards, premium packaging, and high-quality printed materials.

18pt cardstock provides enhanced rigidity and strength, perfect for luxury packaging boxes, product tags, and marketing materials requiring a premium and durable feel.

24pt cardstock is an ultra-thick paperboard delivering maximum strength and premium quality, commonly used for rigid packaging, luxury boxes, and high-end product presentation.

Thin yet durable E-flute corrugated cardboard (1/16") provides a smooth printing surface and reliable protection, making it ideal for lightweight retail and ecommerce packaging boxes.

B-flute corrugated board (1/8") offers excellent strength and cushioning, perfect for shipping boxes, product displays, inserts, and durable custom packaging solutions.

Strong white kraft corrugated stock with a clean printing surface enhances branding while delivering reliable protection for custom printed shipping and retail packaging boxes.

Eco-friendly brown kraft corrugated material provides excellent durability and strength, making it ideal for shipping boxes, inserts, sleeves, and sustainable packaging solutions.

Copper foil stamping adds a warm metallic shine that enhances logos and designs, giving packaging and printed materials a premium and sophisticated appearance.

Gold foil creates a luxurious metallic finish that highlights branding elements and adds an elegant touch to premium product packaging and marketing materials.

Silver foil stamping delivers a sleek metallic effect that enhances packaging aesthetics and makes logos or design elements stand out.

Holographic foil produces vibrant rainbow reflections that create eye-catching packaging designs and add a modern, futuristic look to products.

Debossing presses the design into the material surface, creating a subtle recessed effect that adds texture, depth, and elegance to packaging.

Embossing raises design elements above the surface, creating a bold 3D effect that enhances brand visibility and packaging appeal.

Fluorescent inks produce brighter, glowing colors that instantly grab attention and make packaging designs stand out on shelves.

Spot UV applies a glossy coating to selected design areas, creating contrast on matte surfaces and highlighting logos or graphics.

Matte lamination provides a smooth, non-glossy finish that enhances durability while giving packaging a sophisticated and elegant look.

Gloss lamination adds a shiny protective layer that boosts color vibrancy and makes packaging designs appear bright and eye-catching.

Velvet lamination creates a soft-touch texture that feels luxurious and enhances the premium look of high-end packaging.

Uncoated paperboard offers a natural, eco-friendly texture ideal for sustainable packaging and brands seeking an organic appearance.