Custom Mailer Boxes

The roll-end tuck-front (RETF) corrugated mailer box is the undisputed gold standard of modern e-commerce packaging. Engineered to withstand the rigors of carrier shipping networks while delivering a memorable unboxing experience on the customer's doorstep, our custom mailer boxes put your brand front and center. Whether launching a direct-to-consumer (D2C) subscription service, sending high-touch influencer PR kits, or packaging retail-ready goods, our custom mailers combine structural durability with photo-grade print reproduction.

E-Flute vs. B-Flute Corrugated: Choosing the Right Strength

Selecting the optimal corrugated flute profile ensures your products remain pristine during transit without adding unnecessary dimensional weight:

• E-Flute Corrugated (1/16" thickness): Features 90 flutes per linear foot, providing an ultra-smooth, flat surface ideal for high-resolution graphics, fine typography, and edge-to-edge ink coverage. Perfect for cosmetics, apparel, jewelry, skincare, and lightweight consumer electronics.
• B-Flute Corrugated (1/8" thickness): Offers superior vertical crush resistance and side-wall cushioning. Best suited for fragile shipments, glass jars, canned beverages, candles, and product assortments weighing over 4 to 5 lbs.
• Stock Finishes: Available in Crisp Bleached White (oyster white for vibrant CMYK reproduction), Natural Unbleached Kraft (100% post-consumer recycled for organic appeal), and Deep Solid Kemi Black.

Double-Sided Printing & The Unboxing Experience

In modern e-commerce, the exterior of the box catches attention, but the interior builds brand loyalty. Over 70% of consumers share memorable packaging on social media. Our advanced multi-press capabilities allow full-color printing on both the exterior and interior of your mailer boxes:

• Inside Lid Messaging: Print brand stories, welcome notes, promotional coupon codes, social media handles, and hashtags directly under the lid.
• Interior Flood Printing: Coat the entire interior of the box in your signature Pantone color or bespoke brand pattern.
• Self-Locking Assembly: Built with dust flaps and front roll-end locking tabs that snap securely into place without requiring adhesive tape or glue during fulfillment.

Protective Coatings, Finishes & Embellishments

Elevate your mailer packaging from functional shipping carton to luxury retail keepsake with our suite of premium surface treatments:

• Matte Aqueous Coating: Non-reflective, fingerprint-resistant eco-friendly finish that delivers an elegant, soft aesthetic.
• High-Gloss UV Varnish: Reflective high-shine coating that amplifies color saturation and provides water-resistant protection against transit moisture.
• Soft-Touch Velvet Lamination: A velvety tactile texture that communicates ultra-premium value upon first contact.
• Spot UV & Metallic Foil Stamping: Highlight logos, brand seals, or geometric patterns with reflective gold, silver, rose gold, or raised gloss accents.

Custom Protective Inserts & Compartments

Eliminate bubble wrap and messy packing peanuts. We custom-engineer precision die-cut packaging inserts tailored to the exact dimensions of your merchandise:

• High-Density EVA & EPE Foam: Molded and laser-cut for bottles, cosmetics, and delicate instruments.
• Corrugated Partition Dividers: Segmented compartments for skincare sets, canned products, and multi-SKU retail collections.
• Recycled Molded Pulp Trays: Sustainable, shock-absorbing form-fitted trays made from 100% recycled paper slurry.

Direct Manufacturer Pricing & Sustainable Production

GetPrintedBox is a direct packaging manufacturer, eliminating broker markups. All corrugated stocks are 100% recyclable, biodegradable, and printed using eco-friendly non-toxic soy and water-based inks. With a low minimum order quantity of just 100 units, free structural dieline templates, free 3D digital mockups, and free ground shipping across the contiguous United States, launching custom branded mailer boxes has never been more accessible.