Urgent Custom Boxes

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Custom Corrugated Mailer Boxes

4.5 (5 Reviews)

$0.35

Custom corrugated mailer boxes are self-locking shipping boxes cut from E flute board. The tuck front and dust flaps close without tape and protect products in the mail stream.

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Specifications

DimensionsAll Custom Sizes & Shapes
PrintingDigital (Standard and HD Print), Lithography, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors
Dimensions (L + W + H)All custom sizes and shapes
QuantitiesNo Minimum Order Require
Stock10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock
FinishingGloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling
Additional OptionsEco-Friendly, Recycled Boxes, Biodegradable
Default ProcessDie Cutting, Gluing, Scoring, Perforation
OptionsCustom Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink, PVC Sheet.
ProofFlat View, 3D Mock-up, Physical Sampling (On request)

 

Description

What Is a Corrugated Mailer Box?

A corrugated mailer box is a one-piece folding box made from fluted corrugated board, with a tuck front lid and side dust flaps. It ships products by mail without an outer carton and opens like a lid for unboxing.

E flute board measures about 1/16 in (1.6 mm) thick. The thin flute gives a smooth face for full-color print on the outside and inside. Ecommerce brands, subscription programs and apparel sellers ship in this style.

Corrugated Mailers for Ecommerce and Subscription Orders

The locking tabs keep the lid shut through sorting and carrier handling. Custom inserts hold cosmetics, bottles and accessories in fixed positions. Browse every style in our custom mailer boxes collection, or compare board grades in custom corrugated boxes.

Specifications

BoardE flute or B flute corrugated board, kraft or white liner
DimensionsAny custom length x width x depth
PrintingDigital (Standard and HD), lithography, CMYK, CMYK + 1 or 2 Pantone colors
InksWater-based, soy-based, Pantone, Pantone Metallic
FinishesGloss or matte lamination, gloss AQ, gloss, matte or spot UV, embossing, foiling
Add-onsCustom inserts, window cut-out, gold or silver foil, raised ink
ProofsFlat view, 3D mockup, physical sample on request
Minimum orderNo minimum order quantity
DesignFree design support
DeliveryDHL, FedEx and UPS across the United States

FAQs

Do corrugated mailer boxes need tape?

No. The tuck front locks into the side flaps and holds the lid shut without tape.

Can you print inside a corrugated mailer box?

Yes. We print the inside and outside faces, so the logo or message appears when the lid opens.

Available Options

Order Process

Service support where you need it

Get service support at any point of your packaging journey to guarantee total packaging success.

Consultation

Our experts guide you with tailored advice, stunning designs, risk-free prototypes, and flawless production. We use all materials and also eco-friendly materials to ensure your brand shines.

Design

Our design team creates every kind of packaging, shaped and colored just for you. With Awesome prints and stylish finishes, we make designs that pop. Check out our work at our process.

Prototype

Our prototype team creates sample packaging to test your ideas worry-free. Explore flexible sizes, styles, and prints to ensure your design is perfect before production. Learn how we save you time at our process.

Production

Our production team handles your packaging creation from start to end. They select top-quality, materials and ensure flawless results for a stress-free process.

Logistic

Relax with expert logistics team expertly handling your shipping needs with seamless teamwork. Our dedicated crew crafts organized, cost-saving plans tailored just for you.

Optimization

Unlock smart optimization strategies to save time and money on packaging while boosting eco-friendliness. Our team crafts efficient, green solutions for you.

FAQs

FAQs About Corrugated Mailer Boxes

How do I know when to change from standard mailers to corrugated mailer boxes?


If you start noticing breakages, crushed corners, or packages deforming under weight, it’s a strong sign you need a sturdier structure. Once we review your product types and weights, we can define exactly when corrugated mailers become the safer, more reliable option.

Do corrugated mailer boxes always need tape?


Not always. Many self-locking corrugated designs secure themselves well for moderate weights. For heavier or high-pressure shipments, we may recommend a design that uses both locking flaps and tape for added protection.

Can you print both inside and outside on corrugated mailers?


Yes. Depending on your design and budget, we can keep the exterior minimal and add detailed artwork inside, or print both surfaces for a fully branded unboxing experience.

Do corrugated mailer boxes take up more space to store?


They are thicker than lightweight mailers, but they still arrive flat and stack efficiently on shelves or pallets. We’ll review your storage space and plan batch sizes accordingly to keep inventory manageable.

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How It Works?

With just a few steps, design your own boxes!

Get Free Quote

Get a free quote on any packaging project instantly, no matter how complex it is.

Material Selection

We suggest the perfect packaging material for your box once you select the box style.

Artwork Preparation

Share your artwork & design; if not, we will design it based on your suggestions.

Start Production

Once your artwork is approved, we’ll begin production. We will support you at every step.

Our Capabilities

At Urgent Box Packaging, we are committed to delivering exceptional packaging solutions customized to your needs. From innovative design to seamless delivery, we ensure excellence at every step, bringing your vision to life with precision and care.

Global Sourcing

Price Match Guarantee

3D Design Services

Flexible Lead Times

High-Volume Printing

24/7 Support

Custom Payment Plans

Warehousing & Inventory

Free One Color Printing

Free Design Support

free flat and 3d view

No die and plate charges

Why Choose Us?

Packaging is more than just how it looks

We are committed to making the packaging industry more sustainable and digital. Join our motivated team to contribute to rapid growth and sustainability goals that really make a difference!

40%

Cost & time saved

From industry leading packaging solutions aimed at reducing your time and costs for the best ROI.

50%

Sustainable packaging

By leveraging our green packaging & talented team of structural engineers to minimize material usage.

25%

Increase in sales

With our award winning packaging designers that focus on building effective first impressions.

100%

More reliable service

With our committed packaging specialists that is here for you 24/7 before and after the project.

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