Mailer Boxes

A plain roll-end tuck can work loose over several hand-offs. Add a locking tab or a tape strip if the parcel passes through more than one carrier network — it is a dieline change rather than a cost.

Measure the product rather than the box currently in use. Most operations we quote are running at least one size too large with void fill compensating, and dropping a band saves on every parcel mailer boxes carry.

That is a brand decision, not a cost or protection one. For direct-to-consumer parcels where the customer opens it, print can be worth it. For business deliveries it usually is not.

Only if boxes are arriving crushed. If they arrive intact with damaged contents, the product is moving inside and a heavier outer changes nothing. A fitted insert solves that case, usually at lower cost.

Yes, and for mailer boxes we prefer to specify both together. A cavity that holds the contents still often lets us drop a grade on the outer, so the pair can cost less than an over-specified box alone.

Ordered online, mailer boxes start from $0.30 per unit on our standard build, with free shipping to the US, UK, Canada and Australia. For special sizes, materials or large runs we quote, and for this format the biggest levers are quantity, print route, board grade and how many finishing passes are involved. An insert often lowers the total rather than raising it, because holding the contents still lets us drop a grade on the outer.

Yes. We can send a plain unprinted sample so you can check the fit and structure, or a printed prototype for color and finish. Sample costs are normally credited against the production order. On mailer boxes the thing to check is whether the contents still sit tight once the pack is closed, because movement inside is what causes damage rather than the board grade.

Send the current specification or a physical sample and we will quote to match it rather than proposing an alternative you would then have to re-approve internally. A physical sample tells us more than a specification sheet — board caliper and coating are usually described loosely and measured exactly.

All 50 US states, the United Kingdom, Canada and Australia, on the same timeline everywhere: 3 to 5 business days of production after artwork approval, then 5 to 7 business days in transit. Every run is made to order and shipped directly to your address rather than pulled from stock, so you receive current production rather than whatever has been sitting in a warehouse. Freight is costed separately by weight, volume and destination. If you are shipping to a fulfillment center rather than your own address, send their receiving requirements with the order — pallet height and labeling rules are usually fixed and refusals are expensive.

Every run is cut to your dimensions — there are no stock sizes here. Send the product measurements rather than a box size and we will build the mailer box around them, then send a dieline template you can design onto.

We issue a dieline template sized to your product, prepress checks your artwork against it, and a proof comes back for sign-off. Nothing runs until you approve that proof, and mailer boxes then take 3 to 5 business days.

Yes. Once a first run is approved we hold the board, structure, dimensions, print method and finishes against your account, so a reorder references the same specification exactly rather than being re-derived. It also means a reorder can be priced against a larger quantity without re-opening the specification.