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Custom Mailer Boxes

Custom mailer boxes from Mario Packaging combine reliable protection with a refined presentation. Made using a high percentage of recycled, eco-friendly materials, these boxes are ideal for ecommerce shipping, subscription boxes, and retail-ready packaging. Our custom printed mailer boxes are fully recyclable and designed to showcase your brand with impactful printing, turning every shipment into a professional and memorable brand experience.

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Make a Strong Impression with Custom Shipping Mailer Boxes

Every customer interaction begins with the packaging, which is why custom shipping mailer boxes play a key role in shaping your brand image. Instead of ordinary packaging, professionally designed mailer boxes help elevate your products and create a memorable unboxing experience.

Our custom mailer boxes are made from lightweight yet durable E-flute corrugated material, offering excellent protection for ecommerce shipments. These recyclable boxes arrive flat-packed for easy storage and quick assembly, making them a practical and cost-effective packaging solution for growing businesses.

Custom shipping mailer boxes made from durable corrugated material
Wholesale custom mailer boxes in different sizes, styles, and materials

Explore Affordable Styles and Materials for Custom Mailer Boxes

We offer a wide selection of custom mailer box styles designed to meet different shipping and branding needs. From tuck top mailers and roll end front tuck boxes to fully customized mailer designs, each option is created to deliver secure packaging while maintaining a professional and appealing look.

Our mailer boxes are produced using sturdy corrugated materials such as E-flute for lightweight shipping and thicker board options for added protection. Eco-friendly kraft materials are also available for brands that value sustainability. Choosing the right style and material helps reduce shipping costs, protect your products, and create a strong brand presence at an affordable wholesale price.

Customization Options for Your Packaging

Explore how you can personalize your packaging with different materials, coatings, printing methods, color systems and premium add ons. Combine these options to create custom boxes that match your brand and stay strong in storage, shipping and on retail shelves.

Materials
Materials
Coating options
Coating Options
Printing methods
Printing Methods
Color options
Color Options
Premium add ons
Add Ons


SBS C1S

SBS C1S

Bright white, single coated paperboard engineered for vivid color, crisp graphics and smooth outer finishes on folding cartons and retail boxes.

SBS C2S

SBS C2S

Double sided coated art card that supports detailed printing on both panels, ideal when you want premium graphics inside and out.

Kraft card

Kraft Card

Natural brown card created from a blend of virgin and recycled fibers, finished for clean printing while keeping an eco friendly look.

Textured card

Textured Card

Premium textured paperboard most often used to wrap rigid boxes, giving a tactile, luxury surface with long lasting durability.

Brown flute

Brown Flute

Unbleached corrugated board with natural brown liners, ideal for sturdy shipping cartons and rustic looking retail packaging.

White flute

White Flute

Corrugated board with bright white liners that give you strong protection plus a clean, printable outer surface.

E flute

E Flute

Fine flute profile around 1/16 inch thick, perfect for compact boxes where you need smooth surfaces for sharp graphics.

B flute

B Flute

Thicker flute profile around 1/8 inch, selected for mailers and transit packs that must resist crushing and rough handling.

Grey chipboard

Grey Chipboard

High density grey board made from recycled fibers, used as the core material for luxury rigid presentation and gift boxes.

Duplex chipboard

Duplex Chipboard

Rigid board with a grey back and smooth white face, ideal when you want a printable outer wrap with strong internal support.

Kraft chipboard

Kraft Chipboard

Brown rigid board created from a mix of virgin and recycled pulp, a good fit for eco focused rigid packaging lines.

Gloss coating

Gloss Coating

High shine protective layer that makes colors richer and gives packaging a bright, polished finish.

Matte coating

Matte Coating

A smooth, non-reflective coating that reduces glare and adds a modern, premium feel to packaging.

Blind UV

Blind UV

A clear UV effect applied without ink to create raised patterns and subtle texture under direct light.

Soft touch finish

Soft Touch

A velvety, highly tactile finish that offers a luxury feel while improving durability and scratch resistance.

Digital print

Digital Print

Plate free printing that sends artwork directly from file to press, ideal for short runs, quick tests and frequent design updates.

Offset print

Offset Print

Classic high resolution process that uses plates and a rubber blanket, best suited for larger volumes with consistent colors.

Screen print

Screen Print

Ink is pushed through a mesh stencil to build dense colors, great for bold graphics on specialty materials and textured stocks.

UV print

UV Print

Inks are cured instantly with ultraviolet light, producing crisp details and a durable finish on both coated and non coated boards.

CMYK process colors

CMYK Process

Standard four color system that blends cyan, magenta, yellow and black to create a wide range of tones for full color artwork.

Pantone colors

Pantone Matching (PMS)

Pre mixed spot colors matched to Pantone guides so your brand shades stay consistent from run to run and across materials.

UV ink

UV Inks

Special inks cured with UV light that deliver strong color, fast drying and extra resistance to scuffs and handling.

Embossing

Embossing

Raises selected artwork above the surface of the board, giving logos and patterns a sculpted, three dimensional look.

Debossing

Debossing

Presses artwork down into the material so text and icons sit in a clean, recessed well that feels refined to the touch.

Foiling

Foil Stamping

Uses heat and metal dies to transfer metallic or pigmented foil, adding bright highlights to logos, borders and key details.

Spot UV

Spot UV

High gloss UV coating applied only on chosen areas, creating contrast against a matte or uncoated background.

Custom die-cuts

Custom Die-Cuts

Precision cut windows, shapes and locking styles that let you showcase product details and build unique structural designs.

Clients Testimonials

Our Happy Customers Say It Best

★★★★★

Amazing service and premium quality

The packaging arrived earlier than expected and the print quality is incredible. Mario Packaging really exceeded my expectations.
Lucas Rivera
Lucas Rivera E-commerce Owner
★★★★★

Perfect fit packaging for my products

I ordered custom tuck boxes for my handmade candles. The boxes fit perfectly and look extremely professional. Highly recommended!
Sophie Lane
Sophie Lane Candle Brand Owner
★★★★★

Very cooperative team

They guided me throughout the design and material selection process. The support team truly knows their work.
Daniel Brooks
Daniel Brooks Electronics Brand Owner
★★★★★

Quality printing & smooth finish

The matte finish with embossed logo is stunning. My customers love the new packaging!
Marcus Hill
Marcus Hill Skincare Founder
★★★★★

Affordable and reliable

Mario Packaging gave me the best pricing for bulk mailer boxes. Fast delivery and professional packaging.
Amy Chen
Amy Chen Online Store Owner
★★★★★

Highly consistent quality

I have ordered several times and every batch comes out perfect. Strong material and neat finishing.
Laura Stone
Laura Stone Jewelry Business Owner

Frequently Asked Questions

If you don’t find what you are looking for, feel free to contact us via email and we will be happy to assist.

What are custom mailer boxes used for? Toggle FAQ
Custom mailer boxes are used for shipping and delivering products securely while enhancing brand presentation. They are commonly used for ecommerce orders, subscription boxes, retail shipping, and promotional packaging.
What materials are used for custom mailer boxes? Toggle FAQ
Our custom mailer boxes are made from durable corrugated materials such as E-flute and B-flute. We also offer recyclable and kraft options for brands looking for eco-friendly packaging solutions.
Can I customize the size and design of mailer boxes? Toggle FAQ
Yes. Custom mailer boxes can be fully personalized in size, shape, printing, and finishing. You can add your logo, brand colors, and messaging to create packaging that matches your brand identity.
Are custom mailer boxes suitable for fragile products? Toggle FAQ
Yes. Mailer boxes can be designed for fragile items by using thicker corrugated material, precise sizing, and optional inserts to minimize movement and reduce the risk of damage during shipping.
Do custom mailer boxes arrive flat or pre-assembled? Toggle FAQ
Custom mailer boxes are shipped flat to save on shipping and storage costs. They are easy to assemble and do not require glue or special tools.
Is there a minimum order quantity for custom mailer boxes? Toggle FAQ
Minimum order quantities depend on the box size, material, and printing requirements. Ordering in bulk helps reduce per-unit costs and provides better wholesale pricing.
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