Custom Mailer Boxes
Custom mailer boxes are the corrugated, self-locking boxes that e-commerce orders arrive in: they fold flat, lock without tape, and print on the outside, the inside, or both. Pressholic makes them to your exact length, width and height, in the flute and board you choose, with matte or gloss lamination at no additional lamination charge and a digital proof before anything is printed.
- No minimum order
- 7–14 working-day production
- Free US/UK/CA shipping
- No separate die or plate charges
Mailer boxes at a glance
Each order of mailer boxes is cut from a fresh dieline to the length, width and height you give us — there are no stock sizes to fit into.
- Lamination
- Matte or gloss lamination can be included without an additional lamination charge. Soft-touch lamination is an optional paid add-on
- Minimum order
- Pressholic has no fixed minimum order quantity. We can accommodate small sample runs through to larger production quantities, with pricing based on quantity and specification
- Dies and plates
- No separate charge for dies and printing plates
- Production
- Production 7–14 working days after final approval
- Proof
- Free digital proof (flat mock-up + 3D view); nothing prints until you approve
- Artwork
- .ai .pdf .eps .psd .cdr at 300 dpi
What a mailer box is made of
A mailer box is cut from one sheet of corrugated board — a fluted paper core glued between two liners — so it protects the product without inserts or void fill for most items. Choose a kraft (brown) or white outer liner, an E, B or C flute depending on how much crush protection you need, and add a die-cut insert or divider if the product must not move in transit.
Printing inside and out
The whole sheet is printed before it is cut and scored, so the inside of the lid, the inside walls and the base can carry a message, a pattern or a brand colour at no extra step. Offset and digital printing are both available; finishes such as spot UV, foil stamping and embossing can be added to the outside, and matte or gloss lamination can be included without an additional lamination charge.
Sizing your mailer
Measure the product at its longest, widest and tallest points, then decide how much room it needs around it: a snug fit for rigid items, more space for padding or an insert. The box size calculator turns those inside dimensions into the outside size of a mailer box and lets you download a guide dieline, so you can check the fit before you ask for a price.
Box size calculator
Enter your product size to get the outside size of the box, a guide dieline to download, and pallet and carrier checks. It is free to use and needs no account.
Size your mailer boxesGetting a price
Send the product dimensions (or the size of the box you want), the quantity and the print you have in mind through the quote form. There is no minimum order quantity and no separate charge for dies and printing plates. Free shipping applies to the United States, United Kingdom and Canada; production typically takes 7–14 working days after final approval, and a rush option can shorten that by a few days.
Compare and decide
Guides that help you decide
Is there a minimum order for mailer boxes?
Pressholic has no fixed minimum order quantity. We can accommodate small sample runs through to larger production quantities, with pricing based on quantity and specification. No separate charge for dies and printing plates.
How long does production take?
Production 7–14 working days after final approval. Rush production on request.
Will I see a proof before printing?
Yes. Free digital proof (flat mock-up + 3D view); nothing prints until you approve.
Add-ons & finishes
Finishes that make a box feel expensive
Matte or gloss lamination is included at no additional lamination charge (soft-touch is a paid add-on)
How ordering works
From quote to your door
What happens after you ask for a quote for custom mailer boxes — and when the clock starts.
- 01Request a quoteTell us the product, quantity and size. We reply by email within 6–48 hours with your price and the next steps.
- 02Artwork and proofUpload print-ready files, or let our design team set them up at no charge. You then receive a free digital proof — a flat mock-up and a 3D view.
- 03ApproveCheck every detail and approve the proof (within 24 hours keeps your slot). Nothing is printed before you approve.
- 04Production7–14 working days for printing, finishing and quality inspection. Rush production on request.
- 05DeliveryCarrier transit typically about 6–8 days with DHL or 8–10 days with UPS (estimates, not guaranteed). Free on every order to the US, UK and Canada.
Turnaround
- Production
- 7–14 working days
- Standard shipping
- DHL typically about 6–8 days; UPS typically about 8–10 days (carrier estimates)
- Rush
- Available on request — shortens production by a few days
Production is primarily carried out in Pakistan, with additional production through our manufacturing partner network in China.
Production starts once your artwork is accepted by our prepress team, you have approved the final proof and payment is confirmed.
Worldwide shipping is available. Standard shipping is free on every order to the US, UK and Canada (one delivery address per order). Applicable customs duties and import taxes are covered for the US and UK; for Canada they are the customer’s responsibility; for other destinations, customs duties, taxes and import charges, where applicable, depend on the destination and shipping arrangement and will be confirmed as part of the quote. Transit times are set by the carrier and cannot be guaranteed. Your quote confirms the dates for your exact specification.
How would you like to supply artwork?
We accept .ai, .pdf, .eps, .psd, .cdr (300 dpi minimum). The digital proof is free. A physical sample is available at a small sampling cost if you want to hold the box before the full run.
New to box artwork? See what a dieline is. Choosing a board? Compare corrugated flute types. Not sure which style? See box styles explained. Sizing a shipper? Try the free box size calculator.
