Custom Mailer Boxes
See Custom Mailer Boxes in action
Watch the Custom Mailer Boxes overview from 4OVER4.COM. A short walkthrough of options, premium stocks, live pricing and fast turnaround.
- From $711.78 per 250 boxes, about $2.85 each, with the per-box price sliding to roughly $0.37 as the run climbs to 25,000.
- 2 sizes: 5" x 7" x 1.7" and 5.5" x 5.5" x 2.625", plus a custom size made to order up to 6" x 7".
- 2 materials: 14pt Uncoated Cover with a natural matte surface, and heavier 18pt Cover with Gloss on 1 side.
- Full color printed across the front with a blank back, finished with a Standard Finish.
- 7 business day standard turnaround, with a Free Online Proof, rated 4.7 out of 5 across 12 reviews.
Ship Your Product in a Box Worth Opening
The mailer box is the one part of the order your customer is guaranteed to touch. A plain brown carton says nothing, but a printed mailer wraps your product in your brand from the second the box lands on the doorstep, whether you are shipping an online order, a subscription drop, or a gift set. Custom mailer boxes start at $711.78 for 250, about $2.85 a box, rated 4.7 out of 5 across 12 reviews.
These boxes fold flat until you need them, snap into shape without tape, and print full color across the front where every customer sees it. Want to see how mailer boxes sit next to the rest of our packaging? Browse the full range on custom box printing, or stay here and build yours from the choices below.
The price rewards a bigger run. A set of 250 starts at $711.78, and the per-box cost keeps sliding as the count climbs to 25,000, so a full pallet for a launch costs far less per box than a small test batch. Tap any tier below to see the live run total and exactly how much each step up saves before you commit.
What Are Custom Mailer Boxes?
Custom mailer boxes are folding shipping boxes printed full color to your own artwork, built in 2 stock sizes from 5" x 7" x 1.7" up to 5.5" x 5.5" x 2.625", on 14pt or 18pt cover stock. Brands reach for them when a plain carton would undersell the product inside: e-commerce orders, subscription boxes, product launches, and gift sets. Because the box arrives printed, the delivery does marketing work a blank carton never could. If you are shipping something small and boxy instead, the Golf Ball Boxes cover that shape, and the mailer sits beside them as the everyday shipping option.
Full Color Mailer Box Printing
Full color here means the whole outside of the box is a printed surface, not a panel with a logo dropped on it. Artwork runs edge to edge across the flat sheet before it is cut and folded, so a pattern, a photograph or a solid brand color carries over the corners and down the sides with no white margin at the fold. That is the difference a customer notices on the doorstep: a printed box reads as designed, where a stamped box reads as a plain carton somebody marked.
Against a one color stamp, full color changes what you can put on the box at all. A stamp gives you a mark in a single ink, usually a logo, and nothing tonal. Full color gives you photography, gradients, an exact brand color rather than the nearest available ink, and copy in more than one weight and shade, all in the same pass. There is no per-color setup to add, so a four color design and a one color design print on the same run.
On this product the print is laid down across the front with a blank back, finished with a Standard Finish, so the reveal comes from the outside panels and anything you tuck inside, such as a printed card, tissue or a sticker seal, rather than from a printed interior. Ink does not add time to the schedule: full color is the standard here, so the run holds the same 7 business day turnaround, with a Free Online Proof to check before anything goes to press. Choose between 14pt Uncoated Cover, which has a natural matte surface that suits muted and illustrated artwork, and heavier 18pt Cover with Gloss on 1 side, which holds photography and deep solids with more snap.
What Size Should a Custom Mailer Box Be?
The right size comes down to what you are shipping, since a snug box protects the product and cuts wasted void fill. The 5" x 7" x 1.7" stock size suits flat items like apparel or a small kit, while the deeper 5.5" x 5.5" x 2.625" is closer to a cube for a candle, a mug, or a bundled set. Need something larger or in between? A custom size runs made to order up to 6" x 7". Both stock sizes, the material choices, and the full spec are laid out below exactly the way the live configurator presents them, so you know what you can change before you change it. For a soft pouch-style pack instead, the Pillow Boxes are another small-format option.
Here are a couple of easy ways to make a mailer box pull its weight.
Mailer Box Sizes and What Fits
There are two stock sizes and a custom option, and the depth is what decides between them rather than the footprint. Measure your product with whatever protection goes around it, because the box has to close flat on the tuck flaps.
| Inner size | Shape | What fits |
|---|---|---|
| 5" x 7" x 1.7" | Shallow rectangle | Flat goods: a paperback or notebook, a folded tee or a pair of socks, jewelry in a pouch, a print or card set, a phone accessory, a slim skincare or sample set laid side by side |
| 5.5" x 5.5" x 2.625" | Square, deeper | Anything with height: a candle, a jar, a small bottle in a wrap, a cosmetics trio, a coffee bag, a subscription drop with two or three items stacked |
| Custom, made to order up to 6" x 7" | Sized to your product | A product that wastes space in both stock sizes, or a set that needs an exact fit so it does not shift in transit |
Two things to weigh before you pick. A box that is too deep needs filler to stop the contents sliding, and filler costs money and adds weight on every parcel you ship. A box that is barely big enough is worse: the flaps bow, the lid does not sit flush and the printed panel creases at the corner. If your product sits between the two stock sizes, price the custom option against the cost of packing material across a full run, because at 250 boxes and up the fit usually pays for itself.
Outer dimensions run slightly larger than these inner sizes once the board thickness is counted, which is worth checking against your carrier's rate bands before you commit to a run.
Pick the material that fits the ship
The default 14pt Uncoated Cover keeps things clean and understated, with a natural matte surface you can even write on. Step up to the heavier 18pt Cover with Gloss on 1 side when you want more structure and a smooth gloss face that makes color and a logo snap. Both print full color across the front with a blank back and a Standard Finish, so your brand lands on the surface your customer sees first.
Start from a press-ready blank
Already have your artwork? Skip straight to a press-ready blank instead. Each blank mailer box template is built at the real trim with the fold lines, bleed, and safe margin already drawn in, so your design never crowds a crease or a cut. Grab the size that matches your order below, drop your art in, and upload.
How Much Do Custom Mailer Boxes Cost?
Custom mailer boxes start at $711.78 per 250, about $2.85 a box, and the per-box price keeps dropping as the quantity climbs toward 25,000, where each box lands near $0.37. So how many do you actually need? Drag the slider below to set your count and watch both the run total and the true per-box cost update live, and find the point where one more step up barely moves the budget.
Wally turns the shipping box into the ad
Why a printed mailer beats a plain brown carton every time.
A custom mailer box starts at $711.78 for 250, about $2.85 a box, and it lands on your customer's doorstep wearing your brand instead of nothing. Pick a size, choose 14pt or 18pt cover stock, add full color to the front, and Wally prints the box your customer actually wants to open.
How Do Custom Mailer Boxes Compare to the Rest of the Range?
Custom mailer boxes are the everyday shipping pick, but they are not your only packaging move. If you are weighing a different shape or a specialty box, it helps to see the trade-off in plain numbers. The chart below lines up custom mailer boxes against their closest siblings, including Cannabis Packaging, so you can compare the starting price on each before you choose.
Start from a press-ready blank
A mailer box is a flat printed sheet until it is cut and folded, so the artwork file is built on a dieline rather than on a rectangle. Download the mailer box dieline from the blank templates library and build your design on it, keeping the dieline on its own layer so it can be switched off before you export.
Bleed is the part that catches people out, because a box has bleed in more places than a flat card. Extend every background color, pattern and image past the outer cut edge of the dieline, and past the edge of each tuck flap and side panel too, so no white line appears where the board is trimmed or where a folded panel pulls slightly. Keep logos, copy and anything you would notice being cut well inside the panel and away from the score lines, since a fold running through type distorts it and a mark that lands on a glue or tuck area disappears when the box is assembled. Artwork that crosses a fold on purpose, a pattern or a solid color, is fine and is where a printed box looks best.
Export as a print-ready file with the dieline layer hidden and the artwork at the box's finished flat size, then read the Free Online Proof against the dieline rather than against your screen layout: the proof is where a panel printed upside down or a back face left blank by accident shows up, while it still costs nothing to fix.
How Fast Can You Get Custom Mailer Boxes, and Can You Proof First?
Custom mailer boxes print on a standard 7 business day turnaround, so plan your launch or restock around that window. Before anything prints, you choose how careful to be with the file: pick the Free Online Proof and you get a digital preview to approve before the press runs, or send it Straight To Production when your artwork is already print-ready. A proof is the cheapest insurance on a printed run, and here it costs nothing.
See the Rest of Our Packaging
Custom mailer boxes are one stop in a much larger lineup, and you can scan the full print product range or the wider custom box printing family any time. If a different shape or a specialty stock would serve your product better, the rest of the range is one tap away, each with its own starting price and a link straight to its product page.
The full custom box printing range covers the shapes a mailer box cannot, from retail cartons to product boxes. For an unbleached kraft look rather than a printed white surface, custom kraft boxes take ink differently and suit natural and refill brands, and cube boxes hold a product that is as tall as it is wide, where a shallow mailer would need packing out.
Print Your Custom Mailer Boxes Today
At 4OVER4.COM, quality comes first, and it is backed by 25+ years of printing since 1999. Whatever size and material you pick, these mailer boxes are built to protect what is inside and sell what is outside. Add a Free Online Proof, set your run, and print custom mailer boxes your customers will actually want to open.
