Home / packaging / style / mailer

Mailer Boxes: Definition, Material, Artwork Design, and Printing Methods

Mailer Boxes

Mailer boxes serve as versatile, self-assembling packaging solutions designed for shipping and branding purposes. These boxes are crafted from durable, eco-friendly materials such as cardboard, kraft, and corrugated fiberboard, ensuring product safety during transit. Mailer boxes support customization in design, shape, and size, allowing businesses to align their packaging with their brand identity. They feature advanced printing methods like digital printing, flexographic printing, and offset lithography, alongside premium finishes such as embossing, foil stamping, and UV varnishing. Mailer boxes enhance customer experience with practical styles like tuck-end, roll-over flap, and two-piece rigid designs, incorporating secure closures and easy-to-open features. Lightweight and cost-effective, mailer boxes reduce shipping costs while maintaining their structural integrity, making them ideal for e-commerce and retail sectors. By using recyclable materials, mailer boxes promote sustainability, and their affordability in bulk quantities ensures scalability for growing businesses.

What are mailer boxes?

Mailer boxes are self-assembling packaging containers made of corrugated cardboard used for branding and shipping products conveniently and stylishly. Mailer boxes are mostly used by e-commerce businesses and individuals for sending items through postal or courier services. Custom mailer boxes are made from durable and eco-friendly materials like cardstock, kraft, paperboard, and corrugated fiberboard. These mailer boxes are designed using different printing approaches like spot UV, stamp foiling, embossing, and debossing.
Mailer boxes can be customized in different designs, shapes, and materials to match the brand.

What Materials are Mailer Boxes Made Of?

Mailer boxes are crafted from a variety of sustainable materials, including cardboard, kraft, paperboard, and corrugated fiberboard. Cardboard is particularly favored for its lightweight, eco-friendly, and cost-effective properties, making it ideal for shipping retail and specialty items safely. To further enhance packaging aesthetics, cover paper options like solid color, custom printed, foil, laminated, embossed, matte, and gloss papers can be utilized. These choices allow brands to customize their mailer boxes to reflect their unique visual identity while meeting environmental standards.

Mailer Box

Custom Printed Mailer Boxes 

Mailer Box

Corrugated Mailer Boxes

Mailer Boxes

Mailer Boxes with Logo

Design Artwork for Mailer Boxes

Designing artwork for mailer boxes involves a strategic combination of creativity and branding techniques. Businesses can leverage high-resolution graphics, vivid color schemes, and custom typography to create packaging that stands out. Incorporating your brand’s logo and tagline into the artwork adds a layer of professionalism and reinforces brand recognition. For brands seeking premium finishes, options like embossing, debossing, foil stamping, and UV spot printing can elevate the box design, lending a polished and luxurious look to the final product.

What Printing and Finishing Methods Can Be Used for Mailer Boxes?

Printing and finishing methods for mailer boxes are diverse, enabling businesses to achieve their desired aesthetic and functionality. Common printing methods include:

  • Digital Printing
  • Flexographic Printing
  • Lithography
  • Screen Printing
  • Offset Lithography
  • Rotogravure

Finishing techniques such as foil stamping, UV varnishing, embossing, debossing, and laser printing add depth and texture to the box surface. These methods not only enhance the visual appeal but also contribute to the durability of the packaging.

Promote Brand with Custom Mailer Boxes

Mailer boxes increase brand visibility for businesses. These boxes can be fully customized in design, shape, and material to align with brand guidelines. Incorporating unique imagery, typography, and logos into box artwork ensures a distinct and professional appearance that resonates with the target audience. Branding options include add-ons and personalized features, combined with printing techniques such as spot UV, stamp foiling, embossing, and debossing. These techniques produce eye-catching designs that communicate brand identity while preserving functionality.

Increase Durability with Sturdy Mailer Boxes

Durability is a key feature of mailer boxes as it protects products during transit. Mailer boxes are constructed from high-quality cardboard; these boxes have high folding strength and resist external pressure over extended periods. This sturdiness makes them suitable for shipping fragile or heavy e-commerce products, providing reassurance to businesses and customers. 

Store Products with Added Protection

Custom mailer boxes organize, package, and store products securely while increasing brand visibility. Features such as self-locking tabs and adhesive closures add a protective layer and keep contents intact during transit. For specialized storage needs, customizable options such as compartments, inserts, and dividers can be incorporated to match specific product dimensions and requirements.

Encourage Sustainability with Eco-Friendly Mailer Boxes

Sustainability is a growing priority for businesses and consumers alike. Mailer boxes are produced from recyclable materials such as kraft paper and cardstock, making them an environmentally responsible choice. Selecting eco-friendly packaging supports green initiatives and reduces resource consumption.  

Efficiently Ship Products with Lightweight Mailer Boxes

Lightweight cardboard makes mailer boxes easy to ship and handle. Compact design ensures efficient transportation, reduces shipping costs, and reduces environmental impact. Delivery services are available across the United States, with order tracking for businesses.

Save Money with Affordable Mailer Boxes

Cost-effective options help businesses scale operations. Premium mailer boxes are available at competitive wholesale prices, with bulk order options ranging from a minimum of 100 to a maximum of 100,000 units. This provides flexibility and affordability without compromising quality.  

Why choose PackHit for packaging and shipping products?

Choose PackHit for packaging and shipping to get a complete range of design and customization options to meet all your packaging needs without compromise. At PackHit, we provide you with the options to:

  • Create custom mailer boxes to boost your brand.
  • Select from our durable materials and designs for your mailer boxes.
  • Choose our unique printing techniques to enhance your mailer box design.
  • Verify your order for mailer boxes with our 2D and 3D proofs.
  • Order your mailer boxes in bulk or in smaller quantities as needed.

Customize everything about your mailer boxes by filling out our convenient quotation form.

Scroll to Top