For an online brand, the mailer box is the first thing a customer touches. It has two jobs: get the product there safely, and make the moment of opening feel like part of the purchase. Getting both right comes down to a handful of decisions. Here is how to make them.
1. Start with the inside dimensions
Always size a mailer from the product outward, not from a stock box inward. Measure the length, width and height of your product (or your largest bundle) and add a small allowance for inserts or tissue. A box that fits closely:
- stops items sliding around and getting scuffed,
- needs less void fill, so packing is faster,
- keeps the parcel smaller, which can lower dimensional-weight shipping costs.
If you sell several products, look for two or three sizes that cover most orders rather than one large box for everything.
2. Match the board to the journey
How far and how roughly your parcels travel should decide the material.
- E-flute corrugated is the go-to for most e-commerce. It is thin enough to print well yet strong enough for the postal network.
- B-flute or double-wall corrugated adds cushioning for heavy, fragile or long-distance shipments such as glass jars or electronics.
- Folding cartons (SBS or kraft board) suit light items, or a branded box that ships inside an outer carton.
Not sure which you need? Our corrugated boxes and kraft boxes pages show the most common options.
3. Pick a closure style
The classic roll-end tuck-top mailer folds together without tape or glue and locks shut with a front tuck and side dust flaps. It is quick to pack and opens cleanly, which customers love. If you need extra security, add a tear strip so the box can only be opened once, or a sticker seal with your logo.
4. Plan the unboxing
A mailer has two surfaces to brand. The outside tells the courier, and anyone who sees the parcel, who it is from. The inside is where you can surprise the customer. Popular ideas include:
- a short thank-you message or social handle under the lid,
- a full-colour pattern that only appears when the box opens,
- a printed insert that holds products in place like a display.
Keep the outside simple if parcels are left on doorsteps; a discreet logo is often enough.
5. Choose print and finish to suit your brand
Natural kraft with one or two spot colours gives an earthy, eco look. Full-colour CMYK printing on white board suits bright, playful brands. For a premium feel, add matte or soft-touch lamination, or a foil-stamped logo. Our guide to custom box finishes explains each option.
6. Order a sample before a large run
A digital proof shows your artwork on the dieline, and a 3D mock-up shows how it will look folded. For bigger orders, a physical sample lets you test the fit with your real product and run a quick drop test before committing.
Quick checklist
- Inside size measured from your product, plus room for inserts
- Board strength chosen for weight and shipping distance
- Tuck-top or tear-strip closure
- Outside and inside print planned
- Finish chosen to match your brand
- Proof or sample approved before production
Ready to design yours? Browse our custom mailer boxes or request a free quote with your size and quantity. Orders start from 100 pieces, and our designers will help you place your artwork on the dieline at no extra cost.