The Ultimate Guide to Custom Mailer Boxes

a guide to custom mailer boxes

Product packaging can be as simple or as elaborate as you want. Custom mailer boxes do more than protect your products during the shipping process. They come in different shapes and sizes and can be personalized inside and out to represent your brand. The most popular use for custom mailer boxes is subscription boxes. Companies are able to create a unique unboxing experience, and some even use different designs to follow a monthly theme!

With Custom Boxes Now, possibilities are endless. We have over 60 years of experience creating custom solutions that meet your needs and budget. We are experts in structural design and provide ample printing capabilities to help you create a custom mailer box that protects your product and represents your brand.

What is a Mailer Box?

A mailer box is a type of specialized packaging designed for ease of use and presentation. These boxes are ideal for small- and medium-sized items, and they usually fit through letterbox gaps. Mailer boxes have interlocking flaps that allow for easy assembly and feature a self-locking design that eliminates the need for tape.

Mailer boxes are made of corrugated cardboard, a sturdy material that is 100% recyclable. They have great structural integrity and absorb shock during transportation, offering maximum protection for your products. All these features can be customized to enhance protection and optimize branding potential.

When to Design a Custom Mailer Box

Finding the perfect mailer box for your product can be challenging. This is especially true for products of irregular shape or that have dimensions that don’t quite fit standard sizes. Other times, you want to elevate your brand and stand out in a competitive market.

Custom mailer boxes are tailored to your requirements. They offer the perfect fit for your products and can feature cushioning and extra structural integrity to secure and showcase your products.

Benefits of Using Custom Mailer Boxes

You might be surprised by the big difference your packaging choices make, benefiting your business and elevating your unboxing experiences. Between the wide variety of colors, printing choices and perfect sizing, customization can give your business a great boost.

Some benefits of custom mailer boxes include:

  • Stand out on shelves and online: Creativity is key to creating an eye-catching look, with bright colors, beautiful artwork and witty messaging. Custom design can go a long way in helping your brand enhance its presence in the market.
  • Promote sales: Custom mailer boxes are a two-purpose tool. You can optimize their design to personalize any current promotions and new products to drive your sales.
  • Brand presence and recognition: Customers are looking at more than just your products. Adding custom artwork and using your signature colors in packaging will create a fully branded experience. If customers can recognize your brand just from the box, you know you’re doing something right.
  • Enhanced protection: Custom packaging is built to specifically fit your goods, and it will go the extra mile in keeping items safe and secure throughout the shipping journey.
  • Reduced costs: Mailer boxes are lightweight and easy to assemble. This translates to lower shipping and manual labor costs, especially if you ship in large volumes.
  • Environmentally friendly: These boxes are made from renewable and recyclable materials, making them a sustainable option.

How to Choose the Right Custom Mailer Box

Whether you’re an online store or sell heavy equipment parts, your packaging can enhance your storefront with the right design. Choosing a quality mailer box for your products can show customers how much you care. To create a cohesive look and protective design, you should consider:

Size

To select the right mailer box size, you need to analyze your product’s dimensions and weight. If you plan to ship multiple products, you need to know how to arrange them inside the box and then take their measurements as a group. You should also consider any protective materials necessary, like foam or bubble wrap.

At Custom Boxes Now, we’re specialists in structure design. We can work with images of your products, measurements, existing box specs or receive the physical product to create the perfect box. Our custom mailer boxes can include inserts, partitions or padding to secure, showcase and protect items. 

Design

Custom mailer boxes can come in all colors and be printed inside and outside with whatever design you can imagine. Using your brand colors, logos and designs across the box can enhance the unboxing experience. Printing product details, handling instructions or promotional messages on the box provides helpful information to the customer.

At Custom Boxes Now, we bring your artwork and branding features to life with our extensive print capabilities. We have digital, flexo and litho equipment to meet your needs and budget.

Custom Mailer Box Ideas

Looking at references is a great way to find the inspiration you need to create a unique custom mailer box. We have an extensive portfolio of unmatched custom packaging solutions. Whether you want a minimalistic one-tone design or a colorful mailer box with information about your product, we have a solution for you.

Some innovative mailer box ideas include:

  • Subscription services: Presentation and easy access are crucial for monthly subscription boxes. DateBox’s packaging is fully customized and changes every month to provide a unique experience for couples.
  • E-commerce deliveries: E-commerce is a competitive space that calls for authentic packaging. The Cleveland Cavaliers’ mailer boxes can ship different merchandise while showcasing their team’s identity.
  • Product kits: Custom mailer boxes can neatly accommodate each item. Six Month Smiles created a packaging with clear labels, custom inserts and complete branding optimization for their patient tray kits.

Elevate Your Brand With Custom Boxes Now!

Leverage the power of custom packaging today. Contact Custom Boxes Now for a free quote, or use our Build Your Box tool to create your own custom mailer box.