Home › Custom Boxes › Custom Mailer Boxes
Also known as: Roll End Front Tuck with Dust Flaps (REFT) · RETT · FEFCO 0427
Design custom mailer boxes that up the wow factor while keeping your products secure. See your packaging come to life now with our custom design tool!
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Box Dimensions (inches)
Inside dimensions. Length and width 2 to 20 in, depth 2 to 6 in, in quarter inches.
Material Type
Ink Coverage
How much of the box your artwork covers. A small logo is 0–25% and artwork covering the whole box is 75%+.
Print inside the box as well as outside. A box printed inside only counts as one-sided. Artwork on both sides is priced as full coverage plus the inside print.
Starting at
$0.69/unit
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Design your box in 3DDynamic pricing. Your price updates as you design, based on how much of the box your artwork covers.
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A mailer box is a corrugated box cut and folded from one flat sheet, with a hinged lid that folds down over the front and locks into the side walls. Two dust flaps fold in first, so nothing slips out at the corners. It ships flat and is sturdy enough to travel through the mail on its own. The style is a roll end front tuck with dust flaps, REFT for short, or FEFCO 0427 in the standard catalog of box styles. The same box is sold as a mailing box, an e-commerce box or a subscription box.
Packwire mailer boxes are made from single-wall E-flute corrugated board in White Board, Kraft Board or SuperGloss. They print in full color on the outside, the inside, or both, from 10 boxes up.
| Box style | Roll end front tuck with dust flaps (REFT), FEFCO 0427 |
|---|---|
| Board | Single-wall E-flute corrugated, 32 ECT, about 1/16" thick |
| Surfaces | White Board (most popular), Kraft Board or SuperGloss, with B-flute by quote |
| Holds | Around 40 lb of product. For heavier goods see shipping boxes |
| Closure | Lid front locks into the side walls, no tape or glue |
| Printing | Full color, printed directly on the board, outside and inside |
| Sizes | Any size from 2" × 2" × 2" to 20" × 20" × 6" (inside dimensions) |
| Minimum order | 10 boxes, or one printed sample for $35 plus $6.25 shipping |
| Production | 10 to 20 calendar days after proof approval, plus transit |
| Made in |  The USA, from board with at least 50% recycled fiber |
Every online order ends with a box on a doorstep. A custom branded mailer box turns that moment into the first physical contact with your brand. Your colors, your logo and your message reach them before the product is even out of the box. Custom packaging makes a small shop look established and a growing brand feel consistent, and it keeps the order intact on the way there.
It also travels further than the doorstep. Four in ten shoppers say they would share a photo of a product whose packaging stands out, and those unboxing posts and videos carry your brand to people who have never heard of you. For e-commerce stores, subscription boxes and welcome kits, the mailer box is e-commerce packaging that doubles as marketing you were going to pay for anyway.
Custom mailer boxes come in any size from 2 × 2 × 2 inches to 20 × 20 × 6 inches, in quarter-inch steps, so the box fits the product instead of the product rattling around in a stock size. A snug fit uses less board, costs less to ship, and shows your customer that every detail was considered.
Sizes are inside dimensions, written length × width × depth. The walls add about 1/8 to ¼ inch outside, and we hold a tolerance of 1/16 inch. Our stock sizes all ship as standard parcels with USPS, UPS and FedEx, and odd or oversize custom boxes are welcome too. The carriers' size rules only decide how a box ships, never whether we can make it.
Custom mailer boxes cost from $0.69 per box at the largest quantities to between about $5 and $14 per box at the 10-box minimum, depending on size. A 10 × 8 × 4 inch mailer box on White Board is $7.24 each for 10 and $3.16 each for 500. The table shows our most ordered sizes at those two quantities, priced on White Board with artwork covering up to a quarter of the box. Click a size to open it in the designer.
| Size (L × W × D, inside) | 10 boxes | 500 boxes | Open in the designer |
|---|---|---|---|
| 6" × 4" × 2" | $5.35 each | $1.49 each | Design this size |
| 10" × 8" × 4" | $7.24 each | $3.16 each | Design this size |
| 8" × 6" × 4" | $6.24 each | $2.75 each | Design this size |
| 12" × 10" × 4" | $7.60 each | $3.38 each | Design this size |
| 6" × 6" × 4" | $6.30 each | $2.73 each | Design this size |
| 14" × 10" × 6" | $12.09 each | $5.38 each | Design this size |
| 8" × 2" × 6" | $7.53 each | $3.32 each | Design this size |
| 6" × 4" × 4" | $5.72 each | $2.47 each | Design this size |
| 20" × 16" × 4" | $13.26 each | $5.90 each | Design this size |
Need a size that isn't listed? Enter it in the quote card above. An odd size costs the same as a stock size that uses the same amount of board. Outside what the online designer offers? Request a quote.
There are no setup fees, no printing plates and no tooling, so a run of 10 boxes is priced the same way as a run of 2,000. That is what makes small orders practical, whether it is a welcome kit for 25 new clients, a holiday box for your best customers, or a test run before you commit to thousands. Large runs get the same board, the same print and the same proof process, at a lower unit price.
Five things set the price, and the quote card above shows the effect of each one as you change it.
Size. The price follows the flat sheet the box is cut from, so a deeper box costs more than a wider one of the same volume. The anatomy section below shows why.
Surface. White Board is the baseline. Kraft Board and SuperGloss are priced separately.
Quantity. Order any quantity from 10. Unit prices step down at 25, 50, 100, 150, 250, 500, 1,000, 1,500 and 2,000 boxes. Above 2,000, request a quote.
Ink coverage. The designer measures how much of the box your artwork covers and prices it in four bands, 0 to 25 percent, 25 to 50, 50 to 75, and 75 and up. A small logo sits in the lowest band, and artwork across the whole box sits in the highest, about 10 to 20 percent more.
Inside printing. A box printed on both sides is priced as full outside coverage plus 60 percent, whatever the outside carries. Printed inside only, it counts as one-sided.
All three surfaces sit on the same single-wall E-flute corrugated board, 32 ECT and about 1/16 inch thick. The fine flute gives a smooth face for print, and the three options differ only in the liner, the paper you print on.
Choose White Board for colors that print bright and true, Kraft Board for a natural, unbleached look, or SuperGloss for a coated sheen closer to a retail carton than a shipping box. Hover over the photos to see the texture up close.
Most Popular
A mottled white liner on both faces. Colors print bright and true, and most of our customers choose it.
Premium Finish
A clay-coated gloss liner on both faces, also called Kemi board. Richer color, sharper edges and a retail-shelf sheen.
Natural Look
Unbleached natural kraft on both faces. Colors print softer, which suits earthy palettes and brands that want the board to read as recycled.
Heavy or sharp-edged product? We make the same mailer in B-flute, about 1/8 inch thick, in any quantity. Request a quote with your size, quantity and artwork coverage and we will price it for you.
Transport damage is every online retailer's nightmare. Once an order leaves your shop or warehouse, you need to know it will arrive in one piece. Our mailer boxes are rated for around 40 lb of product and stand up to the drops, sorters and conveyor belts of carrier handling without an outer box.
They are reusable too. A sturdy printed box becomes the place your customer keeps things, and your branding stays on display in their home long after the delivery.
We print directly on the board, edge to edge, on digital presses with UV-cured inks. There are no labels and no laminated wraps, and you can change the artwork between orders at no charge.
Bring your logo and your website's palette into the real world in full CMYK color, with clean lines and fine detail that stay consistent from the first box in the run to the last.
Digital printing on corrugated skips the plates a flexographic press needs and the laminated litho sheet of a wrapped box. That is what lets photographs, gradients and small type print cleanly on E-flute. The ink goes straight onto the liner and cures under UV light the moment it lands, dry and rub-resistant before the sheet is cut and scored.
Every panel is a printable face, from a small logo on a plain box to full-bleed artwork outside and in, and the artwork you upload is the artwork that prints, with no plate, screen or conversion step in between.
Artwork. Vector files (PDF, AI or EPS) or raster files at 300+ dpi, in CMYK, with a quarter-inch bleed. See the artwork guidelines.
Color. Your brand colors, on the box. Full CMYK on digital presses lands close to Pantone® references, close enough that your customers see the brand they already know. Need an exact spot color match? On runs above 2,000 boxes, ask about plate-based printing.
The inside of a custom mailer box is the first thing your customer sees when the lid lifts, and it is yours to print. Inside printing puts a pattern, a welcome line, care instructions or a thank-you under the lid, in the same full-color process as the outside of the box. Add a card or a sample and the product arrives inside an unboxing experience, which is the part people photograph and share.
A mailer box goes together in seconds: fold the base along the scores, roll the end walls in until they lock into the base, pack the order, close the lid and press its tabs into the side walls. No glue, no tape gun, no training. For a busy fulfillment team that is minutes saved on every order, and for a small shop it is one less thing to buy. Add a strip of tape across the front if you want tamper evidence, and it is ready for the carrier.
The flat sheet a mailer is cut from, the blank, is about 3D + 2W one way and 4D + L the other, plus small lock allowances. A 10 × 8 × 4 inch mailer comes from a blank about 28 by 27 inches, close to 5.4 square feet of board, and that area is what the price follows, so depth counts in both directions. Need the production file for a size? Request a dieline and we will email it to you.
Most panels print on the outside of the sheet and show on the outside of the box. The roll-overs are the exception: each one folds over its end wall and comes down inside the box, so what you print on their outside becomes the inside of the side walls. That is why the designer calls them Left (inside) and Right (inside), and why neither they nor the end walls take print on the inside of the sheet. The small tabs disappear into the side walls and carry no print.
| Part | In the 3D designer | What it does |
|---|---|---|
| Front | Outside Front Inside Interior Flap | The lid's front panel, the face of the closed box and the first thing seen when the lid lifts. Its lock tabs hold the box shut. |
| Lid | Outside Top Inside Top (inside) | Hinged to the back, the same size as the base. |
| Back | Outside Back Inside Back (inside) | Rises from the base, and the lid hinges off it. |
| Base | Outside Bottom Inside Bottom (inside) | Length by width. Its two slots take the roll-overs' lock tabs. |
| Inner front | Outside Facing Flap Inside Front (inside) | Stands behind the front panel and shows only while the box is open. |
| End walls | Outside Left, Right Inside Prints from the outside | Form the outside of the side walls. The roll-over covers their inside. |
| Roll-overs | Outside Left (inside), Right (inside) Inside Prints from the outside | Fold over the end walls and come down inside, so their outside print becomes the inside of the side walls. |
| Dust flaps and lock tabs | Outside Side Outside Inside Side Inside | Tuck inside the side walls. Solid color in the designer, no artwork. |
| Tabs | Outside Not printable Inside Not printable | Captured inside the side walls once folded, so they carry no print. |
You don't need a designer or any printing jargon. Pick a size, upload your logo and graphics, add text, and the 3D designer shows the finished box from every angle while the price updates beside it. Save the design to your account, order a printed sample, or go straight to a run.
Every Packwire mailer box is made locally, in the United States, close to the customers it ships to and by people you can reach on the phone. Local manufacturing is what makes the rest possible, from shorter lead times and fewer supply-chain surprises to less freight on every order and the same quality from one run to the next. The board contains at least 50 percent recycled fiber and the finished box is curbside recyclable across the US.
American shoppers say they prefer paper packaging over plastic, and a corrugated mailer is sturdier than a bubble envelope and holds heavier products. Corrugated inserts and partitions, available from 500 units, recycle with the box.
Yes. We offer inside printing on all box styles, and it changes how the box feels when it opens. Brands often use it for thank-you messages, care instructions, social media handles or full interior designs. It uses the same digital process as the outside, so there's no loss in quality.
For mailer boxes, you can design the inside right in our 3D configurator. Two-sided printing is priced as full outside coverage plus 60%. For other box types, pricing depends on the box and the design, so contact us and we'll set it up for you.
Yes. Our mailer boxes are rated to ship on their own. They're made from E-Flute corrugated board, a single-wall build: two flat liners with one fluted layer in between. E-Flute may look thin at 1/16", but that structure makes it strong for its weight. Our mailers are rated at 200 lbs test (32 ECT) and can safely hold up to around 40 lbs of product.
They work with all major carriers, including USPS®, FedEx®, UPS® and DHL®, and they're built to handle those carriers' sorting and handling. Customers often ship clothing, cosmetics, candles, subscription box products, small electronics, food items, jewelry and promotional kits in our mailers with no outer box. The tuck-front closure keeps the box shut in transit, and the corrugated walls give most products enough cushioning. Mailers can ship as is, but we recommend a piece of tape on the closure. It also makes the package tamper-proof.
Yes. Our standard mailer box is E-flute, about 1/16" thick. It prints the sharpest and keeps postage down. If your product is heavy or has hard edges, we can make the same mailer in B-flute, about 1/8" thick, in any quantity. Our team quotes B-flute mailers rather than pricing them in the configurator. Request a quote with your size, quantity and artwork coverage, and we'll come back with pricing.
Yes. A printed sample of your mailer box is $35, plus $6.25 shipping to the continental US, Alaska or Canada. Order it from the 3D configurator by setting the quantity to 1, with your own artwork on it. It is made the same way as a full run, so you can check color, fit and board before you commit.
The minimum order for custom mailer boxes is 10 boxes, and any quantity above that is priced live in the quote card at the top of this page. If you want to see and feel one first, a single printed sample is available. See the sample question above.
Production of custom mailer boxes takes 10 to 20 calendar days, depending on quantity, and starts once you approve your online proof, so the clock runs from approval rather than from checkout. Transit adds roughly one day to a week, depending on your location and order size, so plan on about 2 to 4 weeks door to door. Enter your ZIP code in the quote card to see an estimated delivery date, and confirm exact dates with us before you plan a launch.
Need it sooner? Just ask. If the production schedule permits, we often expedite at no extra charge, and rush options are available for tighter deadlines. Contact us with your timeline.
Five things set the price of a mailer box. They are size, surface (White Board, Kraft Board or SuperGloss), quantity, ink coverage and whether the inside is printed. The quote card at the top of this page shows the effect of each one as you change it, and the pricing section explains them. Above 2,000 boxes, request a quote.
Yes. Our corrugated boards contain at least 50% recycled content, and all our boxes are 100% recyclable through standard curbside recycling. We partner with suppliers who follow responsible forestry practices. Our digital printing is also inherently more sustainable than traditional methods. It uses no printing plates, makes less chemical waste and lets us print only what's needed, which cuts overproduction.
Curious which liners are virgin kraft and which are recycled? The Packaging Board Chart breaks down every paper in a corrugated board.
Mailer boxes we made, in the words of the people who ordered them. Packwire is rated 4.8 out of 5 on Google. More reviews.
WOW! The overall experience turned me into a return customer. The communication was amazing from Phil the entire time. Even letting me know the logo I originally uploaded was printing a little fuzzy, so I was able to correct that and get a flawless finished product. The production and shipping times were easy to track, and it arrived almost a week EARLY! I definitely recommend Packwire Custom for any custom mailer boxes.
Packwire has been so helpful and responsive with their service. Custom boxes aren't cheap but they deliver on quality and our clients love the final product. Zach has been an amazing go-to point of contact for all our questions/needs, I'd rate him 10 stars if I could. Huge thanks to him and the team.
This is our second year ordering mailer boxes with our logo for holiday gifts for our customers. Excellent quality and customer service!
We've been looking for a custom box solution that provided easy to use tools and precise control over the designs. We also hoped for high quality at a reasonable price. Packwire checks every box on our list. We love their online tools and are blown away by the final product and the prices are fanastic. We're VERY happy!
We ordered 100 boxes to use for welcome packages for our company. The boxes turned out exactly as expected. They took a while to come in, but they are great quality and were one of the more affordable ones we came across. Very easy to fold and they close tightly.
I wanted to make custom branded boxes for my merchandise and was so impressed with the boxes I ordered through Packwire. It took me less than a hour to make the design on their website and order the boxes. The boxes match the same colors as my book too!
Your brand deserves packaging that turns heads. Pick a size, upload your artwork and watch your custom mailer box take shape in the 3D designer with the price beside it, full color inside and out, printed on sturdy E-flute board and made in the USA . Start with a single printed sample or go straight to a run, ten boxes or two thousand, with no tooling, plates or setup fees. A few weeks from now your customers are opening a box that is unmistakably yours.
, fast delivery, and backed by our world-class customer service every step of the way. 
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