In today’s competitive eCommerce and retail landscape, packaging is no longer just a protective layer—it’s a branding tool, a customer experience enhancer, and a silent salesperson. One of the most popular and effective packaging solutions in the U.S. market is custom mailer boxes. From subscription boxes to online retail shipping, mailer boxes have become the go-to choice for businesses that value durability, branding, and presentation.
At The Boxology.US, we specialize in manufacturing high-quality custom mailer boxes in the USA, tailored to your product, brand, and budget. This complete guide will walk you through mailer box sizes, materials, customization options, and pricing, helping you make an informed decision for your business.
What Are Custom Mailer Boxes?
Custom mailer boxes are self-locking, corrugated boxes designed primarily for shipping products directly to customers. Unlike plain shipping cartons, mailer boxes are crafted for both protection and presentation. They arrive at the customer’s doorstep looking polished, branded, and intentional—no extra packaging required.
Mailer boxes are widely used by:
eCommerce brands
Subscription box companies
Apparel and lifestyle brands
Cosmetics and skincare businesses
Food and beverage startups
Tech accessories and electronics sellers
Why Choose Custom Mailer Boxes in the USA?
Sourcing custom mailer boxes from a U.S.-based manufacturer like The Boxology.US comes with several advantages:
Faster turnaround times
Consistent quality standards
Lower shipping risks
Easy communication and support
Eco-friendly material sourcing
Most importantly, custom mailer boxes allow your brand to stand out in a crowded marketplace.
Popular Custom Mailer Box Sizes
One size never fits all when it comes to packaging. Choosing the right box size helps reduce shipping costs, prevents product damage, and improves unboxing experience.
At The Boxology.US, we offer fully customizable mailer box sizes, but here are some commonly requested dimensions:
Small Mailer Boxes
Ideal for lightweight and compact products such as:
Jewelry
Cosmetics
Phone accessories
Small electronics
Common sizes:
6” x 4” x 2”
7” x 5” x 3”
Medium Mailer Boxes
Perfect for:
Apparel
Subscription kits
Beauty boxes
Health products
Common sizes:
9” x 7” x 3”
10” x 8” x 4”
Large Mailer Boxes
Best suited for:
Shoes
Clothing bundles
Gift sets
Larger retail items
Common sizes:
12” x 10” x 4”
14” x 10” x 5”
? Pro Tip: Custom sizing reduces void fill, saves shipping costs, and improves sustainability.
Materials Used for Custom Mailer Boxes
The strength, look, and eco-impact of your mailer box depend heavily on the material. At The Boxology.US, we offer premium, industry-standard materials designed for durability and branding.
1. Corrugated Cardboard
The most popular choice for mailer boxes due to its strength and versatility.
Types available:
E-flute (thin, lightweight, premium print quality)
B-flute (stronger, better cushioning)
C-flute (heavy-duty shipping)
2. Kraft Mailer Boxes
Made from natural brown kraft paper, these boxes are:
Eco-friendly
Recyclable
Minimalistic and trendy
Perfect for brands that prioritize sustainability and a rustic aesthetic.
3. White Corrugated Mailer Boxes
Best for bold printing and high-end branding. These boxes offer:
Clean, premium appearance
Excellent color contrast
Professional retail look
Customization & Printing Options
Customization is where mailer boxes truly shine. At The Boxology.US, we help you turn simple boxes into powerful branding assets.
Printing Options
Digital printing (ideal for short runs)
Offset printing (best for bulk orders)
CMYK & PMS color matching
Finish Options
Matte finish (soft, modern look)
Gloss finish (vibrant, eye-catching)
Soft-touch lamination (luxury feel)
Additional Enhancements
Embossing & debossing
Foil stamping (gold, silver, holographic)
Inside printing for premium unboxing
Custom inserts & partitions
Every detail is designed to elevate your customer’s unboxing experience.
Custom Mailer Boxes Pricing Guide
One of the most common questions we get is: How much do custom mailer boxes cost?
The price of custom mailer boxes in the USA depends on several factors:
Key Pricing Factors
Box size & dimensions
Material type & thickness
Printing coverage & colors
Finishing options
Order quantity
Estimated Pricing (General Range)
Small boxes: Starting from $0.50 – $1.20 per box
Medium boxes: $1.00 – $2.50 per box
Large boxes: $2.00 – $4.50+ per box
? Bulk orders significantly reduce per-unit cost.
At The Boxology.US, we offer competitive wholesale pricing with no compromise on quality.
Eco-Friendly & Sustainable Packaging
Sustainability is no longer optional—it’s expected. That’s why The Boxology.US prioritizes environmentally responsible packaging.
Our mailer boxes are:
Made from recyclable materials
Available in biodegradable kraft options
Printed using eco-friendly inks
Choosing sustainable packaging not only helps the environment but also strengthens your brand image.
Why Choose The Boxology.US?
When you partner with The Boxology.US, you’re choosing more than a box manufacturer—you’re choosing a packaging partner.
What Sets Us Apart:
100% custom sizes & designs
High-quality materials
Affordable pricing for startups & enterprises
Fast production & U.S. delivery
Free design support
Low minimum order quantities
We work closely with your brand to ensure your packaging aligns perfectly with your product and vision.
Final Thoughts
Custom mailer boxes are an essential investment for any business shipping products directly to customers. The right size, material, and design can improve brand recognition, reduce shipping costs, and create a memorable unboxing experience.
If you’re looking for custom mailer boxes in the USA, The Boxology.US is your trusted solution. From concept to delivery, we make premium packaging simple, affordable, and impactful.
? Ready to get started? Contact The Boxology.US today for a free quote and design consultation.
