Custom Corrugated Mailer Boxes

Updated 2026-10-06

Custom corrugated mailer boxes are fluted cardboard boxes with a fold-over lid that ship products safely and open like a gift, used by ecommerce, subscription and retail brands. Options include E-flute or B-flute, kraft or white liners, and printing inside and out. Share your size and artwork, and a Vorex specialist replies with pricing.

Ships without an outer carton
E-flute or B-flute strength
Full-color print inside
Custom size to your product

Get a free quote in minutes

Size, quantity and email. We reply with pricing and options.

Ships to the USA and CanadaNo obligation

How corrugated mailer boxes protect and present

A corrugated mailer box is cut from a single sheet of fluted board and folds into a tray with a hinged lid and locking tabs. The wavy flute between two liners absorbs impact and resists crushing, so the box can travel through carriers on its own. That makes custom corrugated mailer boxes a practical replacement for a plain shipping carton plus a separate retail box, saving packing time and giving every order a branded first impression.

Flute choice drives performance. E-flute is thin and prints sharply, which suits cosmetics, apparel and gadgets. B-flute is thicker and handles heavier goods like candles, bottles and kits. Pick a kraft liner for a natural look or a white liner for bright, accurate color. Custom size corrugated shipping boxes reduce empty space, which cuts down on void fill and keeps products from shifting inside the box.

Custom printed corrugated mailer boxes work hardest when the outside is clean and recognizable and the inside carries the story. Put your logo and a short line on the lid, then use the interior for color, patterns, care instructions or a thank-you note. Keep fine text away from fold lines and scores. Our design team can place your artwork on the dieline, and you approve a digital proof before anything is printed.

Popular uses

Direct-to-consumer ecommerce orders
Monthly subscription boxes
Corporate gift and onboarding kits
Cosmetics and skincare sets
Electronics accessories
Food gift boxes with sealed contents

Specifications

Size	Made to your exact inside dimensions (L × W × H)
Materials	Paperboard (SBS), kraft, corrugated (E, B or double wall), rigid chipboard
Printing	Full colour CMYK, Pantone (PMS) spot colours, inside and outside printing
Finishes	Matte, gloss or soft-touch lamination, spot UV, foil stamping, embossing, debossing
Add-ons	Window cut-outs, inserts, handles, custom tissue paper and stickers
Proof	Digital proof on your dieline before production

Request pricing for custom corrugated mailer boxes

Make it yours

Options for custom corrugated mailer boxes

Box styles

Choose a roll-end tuck front mailer, a double-wall front mailer for extra rigidity, or a tear-strip mailer that gives customers a clean, satisfying opening.

Board grades

E-flute and B-flute corrugated are the common choices, with kraft or white outer liners. A specialist suggests the right grade based on product weight and shipping method.

Printing

Full-color printing on the outside, inside or both. Ask about printing techniques suited to your quantity, from bold one-color logos to detailed photographic artwork.

Finishes

Add a matte or gloss coating for scuff resistance, or ask about spot UV and foil details on white-lined boxes for a premium accent on the lid.

Inserts

Corrugated or paperboard inserts hold items in fixed positions, which helps with multi-product kits, glass bottles and anything that should not rattle during transit.

Eco options

Corrugated board is paper-based and widely recyclable where facilities exist. Ask about recycled-content board, kraft liners and water-based inks for a lighter footprint.

How it works

Ordering custom corrugated mailer boxes

Get a free quote

Request a quote
Tell us the box style, size, quantity and where it ships.
Get pricing and a proof
A specialist confirms options and sends a digital proof of your design.
Approve and print
Nothing goes to press until you approve the proof.
Delivered to your door
Boxes ship to your address in the USA or Canada.

FAQ

Custom Corrugated Mailer Boxes: questions answered

Still unsure? Ask a packaging specialist.

What is the difference between a corrugated mailer box and a shipping box?

A corrugated mailer box has a built-in hinged lid and locking tabs, so it opens like a presentation box. A regular shipping box, or regular slotted carton, has four top flaps that need tape. Mailers are chosen when the unboxing moment matters.

Which flute should I choose for my mailer box?

E-flute suits most lightweight to medium products and gives the cleanest print. B-flute is thicker and better for heavier or fragile items. Share your product weight and dimensions, and a specialist will recommend the flute that fits your shipping needs.

Can corrugated mailer boxes be printed on the inside?

Yes. Inside printing is one of the most popular upgrades, because the interior is the first thing customers see when they open the lid. You can print a pattern, a message or full artwork inside while keeping the outside simple.

Can I order custom size corrugated shipping boxes?

Yes. Every mailer is made to your exact length, width and depth. Measure your product, add room for any insert or tissue, and send the inside dimensions. We create a dieline to that size for your artwork.

How do I get a quote for corrugated mailer boxes?

Use the quote form to send dimensions, quantity, board preference, print sides and finish. A Vorex specialist replies with pricing, helps with artwork if needed, and sends a digital proof for approval before production begins.

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