Corrugated Mailer Boxes

Custom Printed Mailer Boxes That Protect and Impress

Your packaging isn’t just functional. It’s an opportunity to connect. Our custom printed mailer boxes are made from corrugated cardboard for strength and durability, with crisp custom printing that makes every delivery memorable. Whether you’re shipping subscription boxes, gifts, or retail goods, these boxes protect your products while showcasing your brand.

At Brown & Pratt, we build packaging that does more than hold your products. It holds attention. Our mailer boxes offer easy and secure closures that serve as a customizable canvas for your brand. With flexible sizes and pricing options, they’re built to elevate the unboxing experience.

Are you launching your first subscription box? Or refreshing an established brand? Our mailer boxes grow with you. We make it easy to create packaging that reflects your values and protects your product. Just as important, it leaves a lasting impression without blowing your budget.

Built to Protect

Durable corrugated cardboard shields your product in transit. Strong enough to stack, ship, and deliver without crushing or bending.

Designed to Impress

Full-color print, inside and out, turns every delivery into a branded experience. Clean folds and sharp edges give your box a polished, professional look.

Flexible & Accessible

Low minimum quantities (MOQs) and a wide range of size options help you ship confidently even at small volumes.

Smart Shipping & Easy Assemle

Self-locking tabs reduce or eliminate the need for tape. Flat shipping and fast folding help streamline fulfillment time and save space.

Get a Free Custom Quote

Your box is your brand in a customer’s hands, so let’s make it count. We’ll help you design mailer boxes that protect your product, reflect your style, and scale with your growth. Let’s build packaging that delivers on every level..

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First Name*

Last Name*

Email Address*

Phone Number*

Company Name

Address

Board Color

Number of Colors Printed

Length

Width

Height

Ideal Order Quantity*

Other Box Sizes*

Check if more than one size is needed

Style

Attach Artwork

Accepted file types: ai, eps, jpeg, jpg, png, pdf, Max. file size: 50 MB.

Additional Information*

Choose the Right Mailer Box

Standard Mailers: Self-locking, front-tuck style boxes with clean edges and strong corrugated walls. A go-to for subscription boxes, eCommerce kits, and promotional packaging.

Slim or Lightweight Options: Designed for thinner or lighter products. Great for flat-packed apparel, printed materials, or promotional items with simple fulfillment needs.

Retail and Gift Mailers: Upgrade with interior printing, custom inserts, or branded seals for a premium unboxing experience.

Custom Sizes: Have a product that needs a just-right fit? We’ll help you build a mailer box that’s precisely built for what you sell.

Customize with Confidence 

Print: 1-4 color process or full-bleed designs, inside and out

Finishes: Matte, gloss, kraft, or soft-touch coatings

Sizes: Standard and custom sizes available, from compact mailers to oversized shipping boxes

Closure: Tuck-in flaps, optional tear strips, or adhesive tape seals

Sustainability: Made from recycled materials and 96% sourced in the USA

Not sure where to start? We’ll help you compare sizes, features, and finishes so you get the perfect box without second-guessing. Our goal is to make high-quality custom packaging easy, even if it’s your first run.

FAQ’s

Things I should know when customizing corrugated boxes:

Quantity

There are always set-up charges which are included in your quote on corrugated boxes. As your quantity increases, it will decrease your cost per box.

Size of item(s) being contained

Weight of item(s) being contained

Printed / Un-Printed

Q: Will my custom manufactured box require one-time tooling charges?

Cutting dies are required for various box types such as mailers, displays, file boxes, and any item that have a self-locking or self-assembling design. There are two types of cutting dies. Flat cutting dies are used for small quantity orders of 1,000 parts or less, and rotary cutting dies, which are used in high speed presses for projects of 1,000 parts and above.

Q: How will the boxes be shipped

Will these boxes be stacked on a skid and stretch wrapped or shipped individually by your choice carrier?

Q: What will my cost be on cutting dies for my box?

Costs for cutting dies vary greatly, depending on the size, complexity, and type of die required. Opening costs start at about $250, but can exceed $1,000 or more. When a project requires a cutting die, we will include the cost as part of our formal estimate. Cutting die costs are only charged one time, and we will store and maintain your tooling at no additional cost.