Mailer boxes made for the doorstep.
Right-sized corrugated mailers with bold print, clean folds and inserts that keep every order secure from packing table to doorstep.
Why Mailer Boxes
The Box That Ships Flat and Locks Into Place
Mailer boxes — also called airplane boxes or self-locking boxes — are the most popular choice for e-commerce brands. They ship flat to save freight, assemble in seconds without glue or tape, and create an instant premium unboxing moment. Whether you sell apparel, cosmetics, subscriptions, or gifts, a custom mailer box gives your brand a packaging experience that customers remember.
Engineered to Snap Together
Self-Locking Wings. No Tape. No Glue. No Tools.
The signature feature of a mailer box is its self-locking side wings. Each panel folds inward and the two side tabs lock into the slotted lid, creating a rigid, secure closure without any adhesive. Your customer simply lifts the lid for an instant reveal.
We precision-die-cut every box from high-quality corrugated or rigid paperboard. The score lines are tested for clean, repeatable folding — no cracking, no misalignment, no frustration.
Printed to Impress
Full-Color Print. Premium Finishes. Your Brand, Front and Center.
Print on the exterior, interior, or both. We apply full CMYK offset or digital printing on kraft, white, or coated corrugated surfaces. Add soft-touch lamination for a velvet feel, spot UV for selective gloss, or foil stamping for metallic accents.
Your logo, pattern, or full-bleed artwork — printed at 300 DPI across every panel. Pantone matching available for brand color consistency. The inside of the lid is prime real estate for a thank-you message or product story.
Mailer Box Styles
Choose the Right Airplane Box for Your Product
Every style ships flat, folds in seconds, and locks securely. All are fully customizable in size, material, print, and finish. Not sure which fits? Tell us your product and we’ll recommend.
Standard Self-Locking（标准自锁飞机盒）
The classic design. Two side wings fold in and lock into the lid. The most popular mailer box style for e-commerce.
Double Wall Self-Locking（双层加强飞机盒）
Extra-thick corrugated walls for heavier products. Same easy assembly, double the protection.
Self-Locking with Insert（带内托自锁飞机盒）
A fitted tray or insert secures your product inside the self-locking shell. Ideal for fragile or premium goods.
Reverse Tuck Mailer（反向插口飞机盒）
Top and bottom flaps tuck in opposite directions. A clean, minimalist look with self-locking side tabs.
Tuck Top Mailer（插口式飞机盒）
A single tuck-in lid replaces the self-locking tabs. Lighter weight, lower cost, same flat-pack convenience.
Roll End Tuck Top（卷边插口飞机盒）
Rounded roll-end edges with a tuck-top closure. A refined look for apparel and gift packaging.
Window Mailer Box（开窗展示飞机盒）
A die-cut window with clear film lets customers see the product before opening. Boosts shelf and camera appeal.
Magnetic Closure with Self-Locking Wings（磁吸自锁飞机盒）
Hidden magnets in the lid add a satisfying snap-close feel while the side wings maintain structural rigidity.
Materials & Board Grades
From Light-Duty to Heavy-Duty — Pick Your Board
Mailer boxes are typically made from corrugated board. The flute grade and paper type determine weight capacity, print quality, and feel.
E-Flute Corrugated
Ultra-thin (1.2mm). Best print surface. Ideal for light products: cosmetics, jewelry, small electronics.
B-Flute Corrugated
Standard (2.5mm). Balance of strength and print quality. The go-to choice for most e-commerce boxes.
BC-Flute Double Wall
Heavy-duty (6mm). Maximum crush resistance. For heavy items: bottles, electronics, bulk orders.
Rigid Paperboard
Premium greyboard (1.5-3mm). Luxury look and feel. Often paired with a wraparound printed liner.
Paper & Print Surfaces
Kraft (Natural Brown)
Eco-friendly, unbleached kraft liner. Best for organic, minimalist, and sustainable brands.
White Top (Coated)
White clay-coated outer liner. Bright, smooth surface for maximum color vibrancy and photo-quality print.
Kemi White Board
Premium white-top kraftliner. Semi-gloss, excellent print quality with the strength of kraft backing.
FSC-Certified Options
All board grades available FSC-certified. Fully recyclable, from responsibly managed forests.
Coatings & Finishes
Aqueous Coating
Water-based, eco-friendly. Protects print from scuffs and moisture during transit.
Gloss / Matte UV
High-gloss or non-reflective matte. Both add a protective layer and enhance shelf presence.
Soft-Touch Lamination
Velvet-like matte finish that customers cannot stop touching. Premium feel for luxury brands.
Foil Stamping / Embossing
Metallic foil accents or raised/debossed textures. Make your logo tactile and memorable.
Why PackagingSmith
Three Reasons Brands Choose Us for Mailer Boxes
Mailer boxes are only as good as the factory that makes them. Here’s what we do differently.
1,000-Piece MOQ
Most mailer box factories require 3,000+ pieces. We start at 1,000, so you can launch a new product, test a design, or run seasonal packaging without overstocking.
1-3 Day Samples
Digital proof in 24 hours. Physical sample with your exact dieline in 1-3 days. Test the fit with your actual product before committing to a production run.
Free Dieline & 3D Mockup
Give us your product dimensions and artwork. We create a print-ready dieline, adjust for material thickness and fold tolerances, and send a 3D rendering — no charge.
Beyond the Box
Upgrade Your Mailer Box Experience
Inside Print
Print a brand message, care instructions, or pattern on the inside of the lid and walls. Turn unboxing into a brand moment.
Add Inside PrintCustom Insert
A foam, cardboard, or molded-pulp insert that holds your product snugly. Prevents shifting, elevates presentation.
Design an InsertEco Upgrades
FSC-certified board, soy-based inks, and water-based coatings. Fully recyclable mailer boxes for sustainability-focused brands.
Go GreenOur Process
From Concept to Your Customer’s Doorstep
Share Product Details
Tell us your product dimensions, weight, quantity, and preferred style. We’ll recommend the best board grade and structure.
Receive Dieline & Quote
Within 24 hours, you get a custom dieline template, 3D mockup, and a detailed quote with shipping, duties, and timeline.
Approve Sample
We produce a physical sample in 1-3 days. Test fit, check print quality, and confirm before we move to production.
Upload Artwork
Send your design files. We adjust for bleed, dieline, and print specs. Free pre-press service included.
Production
7-10 working days. We print, die-cut, fold-flat, and quality-check every box before packing.
Quality Inspection
Random sampling per batch. We check fold accuracy, print registration, color matching, and structural integrity.
Shipping & Logistics
DDP to your door worldwide. We manage freight, customs clearance, duties, and last-mile delivery.
You Receive & Assemble
Boxes arrive flat-packed. Fold the side wings, lock the lid — 3 seconds each. Ready to ship to your customers.
Industries We Serve
Mailer Boxes for Every Product, Every Brand
Apparel & Fashion
Lid-print branding, tissue paper, thank-you inserts. Tuck-top or self-locking styles.
Cosmetics & Skincare
E-flute for crisp print, soft-touch lamination, foam inserts for bottle protection.
Subscription Boxes
Monthly unboxing experience. Inside-print lid, dividers, and branded tissue options.
Food & Snacks
Food-grade liners, grease-resistant coatings, kraft or white-top surfaces.
Candles & Home
Double-wall for glass jar protection. Kraft for rustic branding, matte UV for premium.
Jewelry & Accessories
Rigid paperboard, velvet insert, magnetic closure. Luxury unboxing for small items.
Electronics & Gadgets
Custom-cut foam inserts, anti-static options, double-wall for transit protection.
Gifts & Corporate
Foil-stamped logos, ribbon pull-tabs, premium finishes. Designed to be kept, not discarded.
What Our Clients Say
Trusted by Brands Worldwide
We switched to PackagingSmith for our subscription box mailers. The self-locking tabs snap together cleanly every time. Our subscribers love the unboxing — and our fulfillment team loves that it takes seconds to assemble.
We ship glass skincare bottles internationally. The E-flute mailer boxes with foam inserts solved our breakage problem completely. The soft-touch coating makes the box feel like a luxury gift. Exceeded expectations.
We needed 1,200 kraft mailer boxes for a limited-edition apparel drop. PackagingSmith kept their 7-day promise, and the print registration on kraft was spot on. The boxes arrived flat, perfectly die-cut, and assembly was effortless.
Common Questions
Mailer Box FAQs
What exactly is a mailer box / airplane box?
A mailer box (also called an airplane box or self-locking box) is a corrugated or rigid box that ships flat and assembles without glue or tape. It has side “wings” that fold inward and lock into slots in the lid, creating a secure, rigid structure. The name “airplane box” comes from the side wings that resemble airplane wings when open.
What is the difference between a mailer box and a regular corrugated shipping box?
Regular corrugated boxes typically need tape to seal and have a plain brown exterior. Mailer boxes are self-locking (no tape needed), can be fully custom-printed inside and out, and are designed specifically for e-commerce unboxing experiences. They also tend to use thinner, more printable board grades like E-flute or B-flute.
What board / flute grade should I choose for my mailer box?
For lightweight products (cosmetics, jewelry, small accessories): E-flute is ideal — thin, crisp printing surface, and sufficient protection. For medium-weight items (apparel, candles, subscription boxes): B-flute offers the best balance of strength and print quality. For heavy or fragile items (bottles, electronics): double-wall BC-flute or rigid paperboard are recommended.
What is the minimum order quantity for custom mailer boxes?
Our standard minimum order is 1,000 pieces per design. For certain styles and materials, we can sometimes be flexible. Reach out with your project details and we’ll find the best solution.
Can I print on both the inside and outside of the box?
Yes. Many brands print the exterior with their logo and design, and use the inside lid for a thank-you message, care instructions, or a brand pattern. Inside printing is applied during the same production run, so there is no extra lead time.
How are mailer boxes shipped? Do they arrive assembled?
Mailer boxes ship flat in bundles, which saves significant freight cost compared to assembled boxes. Each box folds into shape in seconds — just fold the side wings inward and tuck the lid. We ship DDP worldwide, handling all customs clearance, duties, and last-mile delivery.
How long does production and shipping take?
Standard production is 7-10 working days after sample approval. Shipping to the US, Europe, or Australia typically takes 15-25 days by sea freight, or 5-7 days by air freight. We’ll provide a full timeline with your quote.
Start Your Project
Let’s Design a Mailer Box That Wows
Request a Quote
Or reach us directly on WhatsApp: +86-XXX-XXXX-XXXX — We reply within 2 hours