Corrugated Mailer Box
The workhorse of e-commerce shipping — a one-piece corrugated mailer that folds into a self-locking box with no tape and no void fill. Fully custom size, print and board grade for subscription, beauty, apparel, electronics and retail brands.
At-a-glance specs
- Structure
- One-piece fold-up mailer, self-locking
- Board grade
- B-flute · E-flute · EB-flute · Kraft
- Thickness
- 1.5 – 3.0 mm (32 – 44 ECT)
- CMYK + Pantone, inside & outside
- Finishes
- Matte / gloss / soft-touch / foil / spot UV
- MOQ
- 500 units (sample: 1)
- Lead time
- 8 – 12 business days + shipping
Built for the way e-commerce shipping actually works
Tape-free closure
Built-in locking tabs snap the mailer shut — no tape, no void fill, faster pack-out.
Ships flat, saves freight
Flat mailers cut storage cube and parcel dim weight versus assembled boxes.
Inside & outside print
Brand the unboxing on both faces — CMYK + Pantone, full coverage, color-matched.
Curbside recyclable
FSC®-certified kraft corrugated — 100% recyclable and plastic-free.
What is a corrugated mailer box?
- (‘Seamless front panel — artwork prints edge to edge, no flap edge showing.’, ‘Ships flat — glued side seam assembles in seconds; saves storage and freight.’, ‘Bold color output — offset CMYK + Pantone or HD digital, proofed before production.’, ‘Earth-friendly — FSC®-certified, curbside-recyclable paperboard.’)
Specifications
| Structure | One-piece mailer — self-locking tabs front and rear |
|---|---|
| Board grade | B-flute · E-flute · EB-flute, tuned to product weight |
| Material | Kraft · White-top Kraft · 100% recycled corrugated |
| Printing | Offset CMYK + Pantone · HD digital · full-bleed |
| Finishes | Gloss / matte / soft-touch lamination · foil · emboss · spot UV · window |
| MOQ | 500 units — price breaks at 1k / 5k / 10k+ |
| Turnaround | 8–12 business days after approval · rush available |
| Free with quote | Custom dieline + physical sample or 3D mockup |
Corrugated board thickness
The flute is the wavy layer between the liners — it decides how thick, stiff and protective your box is.
Frequently asked questions
Corrugated mailer vs shipping carton — which should I choose? +
What is the minimum order quantity? +
How long until I get my boxes? +
Do you help with dieline and artwork? +
Are the boxes recyclable? +
Our Ordering Process
Four simple steps from first inquiry to boxes at your door.
Send inquiry
Tell us size, qty, material & artwork. Get a firm quote + free dieline in 24h.
Proof & sample
We send a digital proof or physical sample for your sign-off before production.
Production
Printed and finished in 8–12 business days with rigorous quality checks.
Delivery
Flat-packed and shipped worldwide, with tracking and after-sales support.
What brands say about our mailer boxes
From indie beauty labels to specialty coffee roasters, hear how teams use our corrugated mailers to deliver a more premium unboxing without blowing up COGS.
“PackagingSmith nailed our corrugated boxes on the first proof. The print quality beats our old supplier and the dieline was free — exactly what a growing brand needs.”
“We reordered four times in six months. The board feels solid in hand and the closures stay tight every time. Customers think the box costs more than it does.”
“Switched from a local printer and saved around 22% on landed cost. The free dieline caught a structural issue before we hit tooling. Worth it on the first run alone.”
Your design covers every face of the mailer
Corrugated mailers are one-piece flat blanks that fold into a seamless box — no flaps breaking up the front. Offset & HD digital print on kraft or white runs bold, full-bleed color across the whole face, inside and out.
See options → Tape-free, presentation-grade closure
The integrated locking tabs snap the mailer shut with no tape or stickers, so you keep a single uninterrupted front panel for your brand, and pack-out stays fast.
Start customizing →Re-order when you need more
The same tooling, the same dieline, the same finish — order only what your launch needs. Standard production runs in 8–12 business days from artwork approval, with free dieline and a firm quote back in 24 hours.
See options → Customers also bought
Complete the unboxing — most orders ship together with these add-ons.
Custom Tissue Paper
Branded inner wrap that turns delivery into an unboxing moment.
View tissue →
Stickers & Labels
Seal tissue, brand the closure or add a thank-you touch.
View stickers →
Pillow Boxes
Light inner packaging for accessories and small gifts.
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Rigid Drawer Boxes
Premium inner box that ships safely inside your carton.
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