Min. 100 units · 3–5 days
32 made-to-order formats
Mailers judged on what they cost to ship, not what they cost to buy
For anyone shipping at volume, the purchase price of a mailer is the smallest number in the calculation. The freight it generates and the damage it fails to prevent are the ones that matter.
- Minimum
- 100 units
- Production
- 3–5 days
- Delivery
- US, UK, Canada, Australia
Which mailer type fits
Four constructions with genuinely different jobs.
| Type | Best for | Where it fails |
|---|---|---|
| Corrugated mailer box | Rigid or fragile goods, branded unboxing | Bulky and heavier than needed for soft goods |
| Poly mailer | Soft goods, apparel, low weight | No crush protection at all |
| Bubble mailer | Small fragile items, documents | Padding adds volumetric weight |
| Rigid mailer | Flat items that must not bend | Expensive per unit for anything else |
The arithmetic that should drive the choice
A mailer that costs three cents more but drops a dimensional weight band pays for itself on the first parcel and every parcel after it. A mailer that costs three cents less and raises damage by half a percent is a bad trade on almost any product value.
Most boxes in service were inherited rather than chosen, so the honest starting point is measuring the product, not quoting a replacement for the box you already use.
Two failures, two different fixes
Crushed boxes mean the board grade is too light for the stack above it. Intact boxes with damaged contents mean the product moved inside, and a heavier outer will not help — a fitted insert will, usually at lower cost because you can then drop a grade on the outer.
Separating those two before changing anything is the difference between a fix and an expensive guess. Tell us which one you are actually seeing.
The range
Custom Mailers We Produce
No format matches that. Try a shorter word, or describe what you need in a quote request.
Specification
Choosing a Mailers Specification
Materials
- Kraft paper outer with bubble lining
- Poly outer with bubble lining
- Recyclable paper-padded lining
- 2.5 mil coextruded LDPE
- 3 mil coextruded LDPE
- 100% recycled LDPE
- Compostable PBAT/PLA film
- E-flute corrugated
Dimensional weight usually costs more than the box itself. Sizing tightly around the product is the cheapest saving available. Our guide to packaging board and film grades compares them on strength, print quality and cost.
Printing
- Flexography
- Digital printing on the outer face
- Digital film printing
- Digital press
- Litho-lamination
- Offset lithography
Run length usually decides this. Digital wins on shorter quantities because there is no plate cost; beyond that, offset and flexo overtake it on price per unit.
Finishes
- Matte outer
- Gloss outer
- Uncoated kraft
- Matte film
- Gloss film
- Metallic film
- Matte lamination
- Gloss lamination
- Soft-touch lamination
- Spot UV
Finishes are applied in the same production run. Each one adds a step, so we price them individually rather than bundling them into the base rate.
Applications
- Small electronics and accessories
- Cosmetics samples
- Books and print media
- Jewellery shipping
- Apparel and soft goods shipping
- Lightweight e-commerce orders
Most orders here come from e-commerce and dtc, apparel and accessories, retail and grocery brands.
Specification builder
Specify your mailers in under a minute
Set what you know, leave the rest. Everything here travels with your request, so nothing gets retyped.
- 100-unit minimum
- 3–5 day production
- Free dieline
- No obligation
YOUR BRAND
Drag to rotate
Recent work
Mailers We Have Produced
Where money leaks on a mailer programme
Five things we find on almost every audit.
- Using void fill to compensate for a box that is simply one size too large.
- Running more box sizes than the product range needs, which multiplies purchasing and pick complexity.
- Shipping soft goods in cartons out of habit when a flat mailer would do.
- Dropping a board grade when the damage is caused by movement rather than crushing.
- Printing the outer for parcels that go to a business address and are opened by a warehouse.
Worth reading before you specify
- finding the dimensional weight band below yoursWhere the recurring saving on a mailer actually comes from.
- trading outer board for a fitted cavityHow to cut damage without adding weight.
Get a price
Quote a Mailers Run
Send the product details and the quantity you have in mind. We reply with a specification and a written price, usually within one business day.
Prices start from $0.30 per piece for large-volume orders. Final pricing depends on size, material, printing, finishes, and quantity.
No obligation
Quote Custom Mailers
Send us the product details and quantity. We reply with a specification and a written price, usually within one business day.
Answers
Custom Mailers Questions
Which mailer type should I choose?
Poly for soft goods with no crush risk, bubble for small fragile items, corrugated for anything rigid or where the unboxing matters, rigid for flat items that must not bend. If more than one fits, the cheapest to ship usually wins.
How much can right-sizing actually save?
It depends how far you currently sit from the band below, but for a seller shipping thousands of parcels a year the freight saving typically dwarfs any difference in the unit price of the box.
Will a lighter box increase my damage rate?
Only if crushing is what damages your product. If damage comes from movement inside the box, a fitted insert lets you go lighter with no increase. Establish which failure you have before changing board.
Should I print my mailers?
It is a brand decision rather than a cost or protection one — print changes neither freight nor damage. For direct-to-consumer parcels it can be worth it; for business deliveries it usually is not.
How many mailer sizes should we stock?
Usually fewer than you do. Every extra size adds purchasing, storage and pick complexity. Send us your product dimensions and we will propose a consolidated set.
Are poly mailers recyclable?
Through store drop-off in many areas rather than kerbside. Mono-material polyethylene is the more recyclable option; mixed-material films generally are not. If recyclability is a stated claim, we will keep to mono-material.
Can you match a mailer we already use?
Yes — send the dimensions or a sample. But it is worth asking whether the existing box is right before we reproduce it, because most are inherited rather than chosen.
What is the minimum order for mailers?
A flat 100 units on any format, which is enough to trial a smaller size against real shipments before switching a line over.
Do you supply plain unprinted mailers?
Yes, and for third-party fulfilment or wholesale despatch it is usually the sensible choice — one plain stock serves every client.
How much do custom mailers cost?
From $0.30 per piece at large volumes. For a shipper the more useful figure is total cost per parcel including freight and damage, which we are happy to work through with you.
Related ranges
Other Categories Worth Comparing
Next step
Ready to Specify Your Mailers?
Send the product dimensions and the quantity you need. We come back with a specification, a lead time and a written price.