Guide / Box & packaging styles / Chapter 2.2
Die-cut mailer boxes.
The box most online brands ship in. Here's how mailer boxes are made, which board and print to choose, and how to get a mailer that protects your product and looks good when it's opened.
The short answer
A die-cut mailer box is cut from one sheet of corrugated board and folds into a box with a hinged lid, usually locking closed without glue. It's strong enough to post on its own and opens like a gift, so it's both the shipping box and the presentation box. Most mailers are made in E flute board for a neat finish and good print. Kraft brown and white mailers are digitally printed from 25 units or screen printed from 250 units, and black kraft mailers are screen printed.
How a mailer box is made
A steel cutting die stamps the box shape and fold lines out of a flat sheet of corrugated board. You fold the sides up, tuck the side flaps in, and close the lid, which tucks in at the front. Many mailers have locking tabs, so they hold together without glue. Those tabs hold the box's shape; for shipping, seal the lid with tape or a sticker so it can't open in transit.
Because the shape is cut rather than folded from a simple rectangle, mailer boxes have neat rolled edges, double-thickness walls in places and a clean lid. That's what gives them their "proper box" feel.
Why online businesses use them
- One box does two jobs. A mailer can be the shipping box and the presentation box, with no outer carton needed for most light to medium products.
- A better first impression. The lid opens like a gift, which makes room for tissue, cards and a branded unboxing.
- Quick to pack. Supplied flat and folded in seconds, then sealed with a strip of tape or a sticker.
- Sizes for postage. Many sizes are made to fit popular postal formats, and we sell boxes sized to fit inside Australia Post satchels.
Choosing your print
The colour of the mailer and the quantity decide the print method. Check the board listed on each product: most mailers are E flute, with B flute on some larger sizes.
| Mailer colour | Print method | Minimum for printing | Lead time |
|---|---|---|---|
| Kraft brown | Digital, or screen for larger runs | Digital from 25 units, screen from 250 units | Digital 5–10 business days (7–10 for made-to-order sizes), screen 10–15 business days |
| White | Digital, or screen for larger runs | Digital from 25 units, screen from 250 units | Digital 5–10 business days (7–10 for made-to-order sizes), screen 10–15 business days |
| Black kraft | Screen, including white ink | From 250 units | 10–15 business days |
What digital printing can and can't do
Digital printing is full colour, but it isn't full coverage. On our kraft brown and white mailers it prints on the top, front and back of the box only, not the side panels, with a 20 mm clearance from fold edges and a maximum print width of 280 mm. It can't print white ink, and it isn't suited to edge-to-edge printing or large solid colour backgrounds. A logo on the lid and a website or tagline on the back works best. See digital printing for the full specifications.
Times above are standard business days from artwork approval. Lead times are longer in peak periods; see our current lead times.
Getting the size right
Mailer box sizes are listed as internal dimensions, length × width × height, in millimetres. Measure your packed product, decide whether it will sit snugly or be wrapped, and choose the closest size. A snug fit protects better and keeps postage down.
If you sell products in several heights, multi-crease boxes have extra fold lines so one box can be set to several heights.
What it means for you
The same question, answered for where your business is today.
Choose your stage at the top of the page to open the advice for you.
Start-up · under 100 units
Start with plain stock mailers in two or three sizes and brand them with a sticker and tissue. When you're ready, a digitally printed run starts from 25 units.
Order a sample of your chosen size and send it to yourself with your product inside.
Growing · 100 to 2,499 units
A printed mailer is often the first custom packaging a growing brand orders. Settle your sizes first, then print the ones you use most.
Try this: compare the cost of plain mailers plus stickers and packing time with a printed mailer quote.
Enterprise · 2,500 units and more
At volume, specify the board, size and print for each mailer, and check how many fit per carton and pallet. Screen printing on kraft brown, white or black mailers starts from 250 units.
Test print colours on your chosen board before a large run.
Common mistakes
- 1Choosing a mailer that's too deep. Extra height means the product moves and the box costs more to post. Choose the closest height, or a multi-crease box.
- 2Overloading a light mailer. E flute mailers suit light to medium products. Heavy items may need B flute or a carton.
- 3Forgetting the inside. The inside of the box is what the customer sees first. Tissue, a card or a sticker makes a big difference.
- 4Printing too many sizes at once. Start by printing the sizes you use most, and keep the rest plain until your range settles.
Mailer box questions
What is a die-cut mailer box?
Do mailer boxes need tape?
What's the minimum order for printed mailer boxes?
How long do printed mailer boxes take?
What board are mailer boxes made from?
From our customers
ArganomicsSelf-locking boxes replaced taping every order, making packing faster and the presentation more consistent.
Read their story →Keep reading
Shop mailer boxes
Ready for your own mailer box?
Send us your product sizes and logo. Our Melbourne team will recommend the size and print method and send a digital proof within 1 business day of receiving your artwork.