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Custom Mailer Boxes
Make every unboxing love at first sight with custom mailer boxes.
- 13 sizes available
- 1/16" white E-flute cardboard
- All-over or logo print options
- 3 print area options: Inside, outside or both
- Durable, with front-tuck closure
- Widely recyclable
Choosing an order type: Place a standard order in any quantity with your full design. Or, try a sample first – a custom-printed box with your design or a pre-printed sample for $1.99 with free shipping. View all packaging sample options.
A personalized mailer
Packaging is everything when it comes to making a strong impression – whether you're an ecommerce business, subscription box brand, event promoter or brick and mortar. Custom mailer boxes turn a simple delivery into a moment worth sharing. Think unboxing videos, repeat customers and a brand that sticks in people's minds. They're doing real work behind the scenes too. The corrugated E-flute construction keeps dust, moisture and impact at bay, so your products show up looking as good as when they left your warehouse. Personalize it inside and out, and every unboxing becomes a moment your customers remember.
A variety of options
With 13 sizes, 3 print types and flexible print areas, there's a custom printed mailer box for just about anything you're shipping. All-over print gives you full-coverage colour, patterns or graphics. Logo print keeps things clean with a branded touch. Samples let you try before you commit. Print inside and outside, outside only or inside only, whatever works best for your unboxing experience. Every style is made from 1/16" corrugated E-flute cardboard (32 ECT edge crush test rating). Sturdy and crush-resistant, it's built for small to mid-sized items. Smaller boxes work well for jewelry, cosmetics and gift sets. Larger ones handle apparel, multi-item orders and subscription programs. Pick your size based on what's going inside and how far it's traveling. They're widely recyclable, built to last and the front-tuck closure makes opening feel like an event every time.
From design to delivery
Upload your logo, graphics or full design to our 3D studio, pick a size and print type, and we'll handle the rest, from printing to your door. For best results, use artwork at 300 DPI or higher with a 0.125" bleed zone. Colours can shift slightly in print, so richer, deeper tones tend to come out most vibrant. Pick your timeline once your design's ready. Economy ships in 8 business days, standard in 6 and express in 3. Prices start at $12.99, and orders over $75 ship free.
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See our “Overview” section for a video that walks through assembling your mailer for the first time.
Upload your logo, image or full design to our online design studio and use the editor to customize your look. Remember to remove any die-lines from your file before uploading, otherwise they will be printed with your design.
For best results:
- Use artwork at 300 DPI or higher in CMYK colour mode
- Include a 0.125" bleed zone
- Avoid thin fonts or low-contrast designs on corrugated material as these can lose definition in print
- Keep in mind that colours may shift slightly between screen and print – deeper, richer tones tend to come out most vibrantly
The weight of each mailer varies by size. See the chart below:
- 5" x 3" x 1.5" weighs 1 oz.
- 6" x 4" x 3" weighs 3 oz.
- 6" x 5" x 2.25" weighs 4 oz.
- 7" x 5" x 3" weighs 4 oz.
- 8" x 6" x 3" weighs 5 oz.
- 8" x 8" x 5" weighs 7.4 oz.
- 9" x 6" x 4" weighs 5 oz.
- 9" x 7" x 2.25" weighs 5 oz.
- 9.5" x 7.75" x 4" weighs 8 oz.
- 11.25" x 9" x 3" weighs 8 oz.
- 12" x 9" x 2" weighs 9.1 oz.
- 12" x 10" x 4" weighs 9.6 oz.
Full-print mailer boxes cover the entire surface of the box with your design – inside, outside or both – giving you maximum space for bold graphics, images and text. Logo mailer boxes feature your logo or branding on designated print areas on a white box. Both are a strong fit for brand presentation, whether you're shipping ecommerce orders, subscription boxes or PR kits. And both options are available in 13 sizes with a front-tuck closure, in quantities as low as 1.
E-flute is very thin (1/16") corrugated cardboard. It’s very easy to fold and is excellent for printing. Sturdy and crush resistant, it’s a good option for shipments – we do not recommend these mailers for very large or heavy items.
Yes, you can order 1 custom-printed mailer box to check the quality of your unique full-print or logo design in print. You can also order sample mailer boxes in all our available sizes – we'll send a box pre-printed with a sample design for $1.99 with free shipping, so you can get a feel for the quality and try out different sizes before placing your full order. Samples are a low-risk way to test a size or finish before committing to a full production run of your custom printed mailer boxes. View all packaging sample options here.
The size listed always refers to the interior dimensions – so a 6" x 4" x 3" box fits items up to 6" long, 4" wide and 3" deep. Outside dimensions are slightly larger to account for cardboard thickness.
As a general guide:
- Small (5" x 3" x 1.5" – 7" x 5" x 3"): Best for jewelry, small accessories, cosmetics and skincare samples.
- Medium (8" x 6" x 3" – 9.5" x 7.75" x 4"): Best for candles, books, stationery sets and small gift sets.
- Large (11.25" x 9" x 3" – 14" x 12" x 5"): Best for apparel, larger gift sets and subscription box orders.
For full inside and outside dimensions across all 13 sizes, click on Sizes & Dimensions below the product options. Not sure which size is right? Order a single box with your design or a pre-printed sample.
Yes. Both all-over print and logo mailer boxes support inside printing, outside printing or both. Logo mailer boxes feature a clean white interior and exterior. Printing on both sides is one of the easiest ways to elevate the unboxing experience without adding extra branded packaging materials. You can preview your design before checking out.
Yes, VistaPrint’s custom mailer boxes are widely recyclable, based on many recycling programs. This may vary depending on the area in which you are using and trying to recycle our products, so we recommend you check in with local resources and recycling programs to confirm.
Orders of 3,000 units or less are produced within 6 business days if ordered after 9am. Production timelines for larger quantities vary by box size and season. You can also choose your shipping option at checkout: economy (8 business days), standard (6 business days) or express (3 business days).