The Complete Guide to Custom Mailer Boxes
Everything you need to know about designing, ordering, and using custom mailer boxes for your e-commerce business.
TPW Team
The Printing World editorial team.
Custom mailer boxes have become the gold standard for e-commerce packaging. They offer a perfect combination of protection, branding, and unboxing experience.
Why Custom Mailer Boxes?
In today's competitive e-commerce landscape, your packaging is often the first physical interaction a customer has with your brand. A well-designed mailer box creates a memorable unboxing experience that encourages social sharing and repeat purchases.
Choosing the Right Size
Selecting the right box size is crucial for both cost efficiency and product protection. We recommend measuring your product and adding 1-2 inches of padding on each side.
Design Best Practices
- Keep your logo prominent but not overwhelming
- Use colors that align with your brand identity
- Consider the interior print for a surprise unboxing element
- Include care instructions or thank-you messages
Material Options
Mailer boxes are typically made from corrugated cardboard (E-flute or B-flute) for durability, or rigid cardboard for a premium feel. Both options can be fully customized with your branding.