Mailer Boxes

FREE Custom Sample (Only pay shipping)
Full Color Printing
Easy 3D Design Tool
Flexible Quantities
Fast Turnaround - 10 Days or Less

Wow Customers with Custom Printed Mailer Boxes

Custom mailer boxes elevate your brand to the next level and create a memorable unboxing experience for customers. When a colorful, branded box arrives to your customer's mailbox, they'll be even more excited about what's on the inside. Mailer boxes are lightweight yet durable boxes perfect for e-commerce, subscription boxes, and promotional items to clients. Custom mailer boxes are printed on white corrugated D flute cardboard to allow for beautiful, full color printing. With whitecardboard on both sides, you can choose either full color printing outside only or full color printing outside and inside.

Uses for Mailer Boxes

E-Commerce Orders
Subscription Boxese
Employee Onboarding
Welcome Packages
Trade Shows and Conferences
School Boxes

Mailer Box Printing FAQ

Can I get a custom printed sample?
You bet! Simply select a quantity of 1 on our pricing calculator above to order a custom sample with your artwork. Then, create your design online and see an instant 3D model of your finished design.

Do you offer custom sizes for mailer boxes?
At this time, we are not offering custom sized boxes. However, we plan to offer more sizes soon - be sure to subscribe to our newsletter so you can stay in the know on when we launch new sizes.

What material are these printed on?
Our mailer boxes are printed on D flute cardboard, an innovative type of corrugated fluting that is a great option for many types of packaging used in eCommerce and retail settings. D Flute offers a superior printing surface while also providing protective qualities to sustain rough handling during shipping. Its slim profile allows for companies to save on warehouse space in addition to allowing a lighter package weight to help on shipping costs. D Flute is also environmentally friendly as is it is made from 100% recycled paper.

Can I add printing to the inside of my box?
Absolutely! Our boxes are printed on white cardboard, both sides, to allow for beautiful full color printing inside and out. To include inside printing, please select "Full color inside and outside" as your printing option on our instant pricing calculator above.

Mailer boxes are made from D flute cardboard, a strong corrugated cardboard material with a superior printing service and protective qualities. Our cardboard is white on both sides, so you can enjoy beautiful full color printing both inside and out. D flute is a flute profile that is smaller and closer together as compared to B flute.

To prepare your custom box artwork, you can use our online design tool or prepare your design offline. For more experienced designers, offline design can provide additional customization for your artwork.

For offline design, first download the correct size box template using our pre-made dielines. (Click the tab labeled "Templates" to download).

Resolution: 300 PPI for all images

Bleeds: Ensure your artwork extends to the red "bleed" line (the outline set to .25" away from the entire dieline)

Color Values: CMYK values only

Safe Area: We recommend keeping critical text and elements .25" away from the fold lines

Text Sizes: We recommend a minimum of 10 pt text size for best readability

Acceptable File Formats: .pdf, .psd, .png, and .jpg

Uploading files: Using our downloadable templates, you will first upload the outside (front) file. Next, if you choose to add inside printing, you will upload the inside (back) file. If you are not adding inside printing, you do not need to upload a separate inside file.

If you need any help with creating your print ready artwork, please give us a call at 800-227-7377 or email us at info@uspress.com.

Proofing: After you place your order and upload your artwork, our prepress team will begin inspecting your files to ensure your document size, bleed lines, margins, image resolution, and more are correct in order for the best print quality. They will email you a soft proof (PDF) for your approval prior to printing. Most proofs are sent within 1 business day of order placement; more complex art files can sometimes take longer. Soft proofing is an easy way to see what your finished product will look like and make sure the content is correct. However, soft proofing is not intended for exact color matching. Every monitor displays color differently, and on backlit screens, colors may appear lighter than the actual colors contained in your files. If color matching is critical, please give us a call at 800-227-7377 to order a hard proof.

Production Time: Production time begins after proof approval and is the time required to produce your order before it ships. It is calculated in business days, starting at the next occurrence of 9:00 AM Eastern on the 1st business day after the proof is approved. U.S. Press is closed Saturdays, Sundays and all major holidays; thus, these days are not included in the production schedule.

Shipping Transit Time: Once production is complete, your order will ship out via the shipping method you select at checkout. All of our orders ship from our location in Valdosta, Georgia. The transit map below shows expected transit time from our plant in Valdosta to your location based on FedEx Ground shipping. Alternatively, you can select an expedited shipping method (FedEx Express Saver - 3 business day transit), FedEx 2nd Day Air (2 business day transit), or FedEx Overnight Standard (1 business day transit).