Custom printed mailer boxes with vibrant full-color CMYK & Pantone branding for a standout unboxing. USA-made, zero MOQ & free shipping. 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 printed mailer boxes turn every shipment into full-color brand advertising, so the box sells your brand before it is even opened.
A plain shipper wastes the one branded moment every customer sees, while a printed mailer makes the delivery feel intentional and shareable. At Apexio Packaging, we make custom printed mailer boxes in the USA for e-commerce, DTC, subscription and retail brands. 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 print quality.
Get your free quote and free 3D design proof today – email sales@apexiopackaging.com.
A printed mailer box is a corrugated shipping box decorated in full color inside and out with your brand artwork.
The corrugated shell protects the product in transit, while high-resolution print on both faces carries your logo, colors, patterns and message. Inside printing turns the reveal into a branded moment, which is why printed mailers dominate branded e-commerce.
Printed mailers suit any brand that wants shipping to double as marketing.
E-commerce and DTC brands use them to stand out on the doorstep, subscription companies use them for a repeatable branded unboxing, and retail brands use bulk runs for consistent identity. For a bold monochrome look, compare our custom black mailer boxes.
The right printed mailer style depends on how it opens and how much print surface you want.
| Mailer style | Best for | Why it works |
|---|---|---|
| Roll-end tuck front (RETF) | E-commerce and subscriptions | Large print faces, tape-free close |
| Self-locking mailer | High-volume shipping | Locks flat, fast assembly |
| Front-tuck mailer | Light retail items | Clean face for hero artwork |
| Die-cut mailer | Gifting and PR kits | Custom shape and print surface |
| Literature / book-wrap | Apparel and flat goods | Snug wrap, low DIM weight |
A roll-end tuck front gives the largest print faces for daily shipping, while die-cut mailers suit PR kits. For heavier goods, compare our custom corrugated mailer boxes.
Printed mailers are cut to any product, and the chart shows common sizes in inches.
| Box size (L x W x H) | Fits | Common use |
|---|---|---|
| 6 x 4 x 2 in | Cosmetics, small goods | 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 |
We size each printed mailer to the product so artwork wraps cleanly and the box sits snug, cutting movement in transit and keeping dimensional (DIM) weight low. Fully bespoke sizes are cut on request.
Printed mailers are built on corrugated board, chosen by product weight and shipping distance.
| Board / flute | Thickness | Typical ECT | Best for |
|---|---|---|---|
| E-flute | ~1.5 mm | ~32 ECT | Light retail items up to 2 lb, sharp print |
| B-flute | ~3 mm | ~40-44 ECT | Standard e-commerce, 2-5 lb |
| Double-wall (BC) | ~6-7 mm | ~48-51 ECT | Heavy or multi-item kits |
E-flute gives the smoothest surface for fine, full-color print, while heavier flutes carry more weight. FSC-certified stock is available. We do not print on thin greyboard or cardstock, because only corrugated survives the parcel network.
We print mailers by three methods, chosen by run size, detail and budget.
| Printing method | Best for | Main strength |
|---|---|---|
| Digital | Short runs, samples, fast launches | No plates, full color, quick |
| Offset (litho-lamination) | Photographic art, premium retail | Sharpest detail on a bonded liner |
| Flexographic | Large-volume runs | Best value, strong spot color |
Digital suits short branded runs, offset litho-lamination delivers photographic quality, and flexo prints directly onto corrugated for the best value at scale.
| 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 |
Full-color art is built in CMYK, while Pantone (PMS) matching locks a signature brand color so every reorder matches. RGB is screen-only. Our CMYK, PMS and RGB color guide explains it.
Finishes make printed artwork pop and protect it from transit scuffs.
| Finish | Effect | Best for |
|---|---|---|
| Gloss lamination | Vivid, high-shine color | Bold photographic art |
| Matte / soft-touch lamination | Muted, premium feel | Minimalist and luxury brands |
| Spot UV | Glossy accent on matte | Logos and highlights |
| Foil / embossing | Metallic and tactile accent | Hero SKUs and gifting |
Gloss makes full-color artwork vivid, matte and soft-touch feel premium, and spot UV, foil and embossing add an accent to your logo.
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 printed unboxing.
| Insert / add-on | What it does | Best for |
|---|---|---|
| Die-cut foam (EPE / EVA) | Firm shock protection | Fragile and tech goods |
| Corrugated dividers | Separates multiple items | Kits and sets |
| Tear-strip opening | Easy, tool-free open | Subscription unboxing |
| Printed insert card | Message, promo or QR code | Marketing and loyalty |
Foam and dividers protect and organize, a tear-strip makes opening easy, and a printed insert card extends the branded moment with a promo or QR code. For small luxury goods, see our custom jewelry mailer boxes.
Printed mailers are engineered for the parcel network, so they protect goods and market your brand.
A right-sized printed mailer protects against drops and stacking, removes rattle and keeps dimensional weight low, so you cut damage claims and shipping cost. On arrival the full-color exterior and printed interior drive repeat orders and social shares. Explore every structure on our custom mailer boxes hub.
Ordering printed 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, 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 check every printed mailer for color, board strength, fit and fold before it ships.
We confirm color accuracy, print registration, ECT rating 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.
Make every shipment sell your brand. Start with zero risk: no minimums, free design, a free 3D mockup and free US shipping. Send us your artwork and product, and we turn it into custom printed mailer boxes that survive transit and own the unboxing. Get your free quote now – email sales@apexiopackaging.com.
| Box Style | Custom Printed 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.