Custom Mailer Boxes for E-commerce: Sizes, Materials & OEM Pricing

For direct-to-consumer brands, the custom mailer box is the unboxing moment — and the most shared asset on social. Here is how to specify mailer boxes for an OEM production run without overpaying.

Mailer Box vs Shipping Carton

A mailer box is a self-locking, branded shipper that needs no tape; a shipping carton (RSC) is a plain outer used for logistics. Many brands use a printed mailer inside a plain carton for international freight. Compare our e-commerce mailer box and RSC shipping carton.

Materials & Flute

• E-flute / F-flute: thin, smooth, ideal for retail-grade print.
• B-flute: more cushioning for heavier items.
• Kraft vs white: kraft for eco positioning, white for clean colour print.

Common Sizes

S, M, L mailers typically cover 150–350 mm on the long edge. Right-sizing reduces void fill and shipping cost — the single biggest hidden saving in e-commerce packaging.

Printing & Inserts

Outside print carries brand colour; inside print can carry a thank-you or how-to. Card inserts, tissue and stickers are low-cost ways to lift perceived value. All are manufacturable under OEM with your artwork.

MOQ & Pricing Drivers

Mailer MOQs often start near 500 units. Price is driven by board grade, print coverage (1-colour vs full), flute and any lamination. Tooling is a one-time die cost.

Conclusion

A well-specified mailer box protects the product, reduces freight cost and earns social shares. Send your product dimensions and we will propose a right-sized structure and quote. See the full packaging catalogue for related formats.