Custom Mailer Boxes

Custom Mailer Boxes UK

Turn every online order into a professional branded delivery with custom mailer boxes from All Custom Packaging. Made for e-commerce shops, subscription services, retailers and growing product brands, our mailer boxes combine secure corrugated construction with a clean, memorable unboxing experience.

Each box is cut around your product dimensions rather than restricted to a small selection of stock sizes. This creates a closer fit, reduces unnecessary empty space and helps you avoid using more internal filling than the product requires.

Your branding can run across the outside and inside of the box, including the lid, base and internal panels. Use the available space for logos, patterns, product information, thank-you messages, promotional offers or reorder QR codes.

Why E-Commerce Brands Choose All Custom Packaging

For many online businesses, packaging is the first physical interaction a customer has with the brand. A stock brown shipping box may complete the delivery, but a printed mailer creates a more considered experience from the moment the parcel arrives.

All Custom Packaging produces custom mailer boxes from 100 units per design, making professionally branded packaging accessible to independent online shops, product launches and subscription businesses.

Our service includes:

• Boxes cut to your product dimensions
• No setup fees
• Free packaging design support
• A free 3D mockup
• Printing inside and outside
• Custom materials and board strengths
• Physical sample video approval
• Production in 6 to 8 business days after design approval
• Free delivery throughout the UK

Before the full run is printed, you can review a video of the physical sample. This allows you to check the size, structure, closure and printed appearance before approving production.

Custom Mailer Box Styles

The best mailer format depends on the product weight, packing process, delivery journey and experience you want the customer to have.

Printed Mailer Boxes

Custom printed mailer boxes provide a strong corrugated structure with a large printable surface for your branding.

Printing can cover the exterior only or continue across the interior for a complete branded reveal. These boxes are suitable for clothing, cosmetics, gifts, accessories, stationery, wellness products and subscription orders.

Explore:

• White Mailer Boxes
• Tuck Top Mailer Boxes

White board provides a clean base for bright colours and detailed artwork, while kraft board creates a more natural presentation.

Self-Seal Mailer Boxes

Our Self Seal Mailer Boxes include a peel-and-stick adhesive strip, allowing the box to be closed without applying separate packing tape.

This can speed up repetitive packing tasks and create a neater external appearance. Self-seal boxes are particularly useful for e-commerce businesses packing a high number of similar orders from a fulfilment bench.

A tear strip can also be considered for suitable structures, giving customers a simple and controlled way to open the parcel.

Tab-Lock Mailer Boxes

Tab-lock mailers use folding side panels and locking tabs to create a secure box without relying on glue during assembly.

Explore White Tab Lock Mailer Boxes for subscription products, gift sets and branded e-commerce deliveries.

The classic fold-and-lock format provides:

• Quick manual assembly
• Secure side walls
• A clean tuck-front closure
• A wide printable lid
• A structured unboxing experience

Tab-lock boxes are supplied flat, helping reduce the storage space required before they are assembled for use.

Rigid Mailer Boxes

Rigid flat mailers provide additional stiffness for products that should remain flat during handling and delivery.

Explore:

• Rigid Mailer Boxes
• Record Mailers

These formats are suitable for:

• Books and magazines
• Vinyl records
• Art prints
• Photographs
• Documents
• Calendars
• Catalogues
• Flat media products

The dimensions can be adjusted around the item to limit movement and help protect corners and edges.

Coloured Mailer Boxes

Pre-coloured board can create a strong branded appearance without covering every surface in full-colour print.

Explore:

• Red Mailer Boxes
• Teal Mailer Boxes
• Yellow Mailer Boxes

A logo, short message or simple design can be printed over the coloured surface. This approach works well for brands with one strong signature colour or businesses seeking a bold but uncluttered presentation.

Sustainable Mailer Boxes

Our Sustainable Mailer Boxes can be produced using recycled or recyclable board options selected according to the required construction and print.

Keeping the box closely sized to the product can also reduce unnecessary board and void-filling material. Recycling or disposal guidance can be printed directly onto the box to help customers handle the packaging correctly.

Recyclability depends on the final combination of board, finishes, adhesives and local collection facilities, so material claims should be confirmed against the chosen specification.

Made to Your Product Size

A mailer box should protect the product without making the customer receive a parcel filled mostly with empty space.

We use the dimensions of your product or packed arrangement to develop the box size. This is useful for individual products as well as subscription boxes containing several items.

Custom sizing can help:

• Keep products more organised
• Reduce unnecessary movement
• Limit the amount of void filling required
• Improve the visual presentation when opened
• Use storage space more efficiently
• Avoid paying to send an unnecessarily large parcel

When several products will be packed together, provide their intended arrangement as well as the overall dimensions. Inserts or dividers can be developed where individual components need to remain separated.

Mailer Box Sizes and Board Options

Item	Detail
Sizes	Made around your product, from compact letterbox-friendly formats to larger subscription and e-commerce boxes
Standard board	E-flute corrugated board for lightweight and medium-sized products
Heavier products	Stronger grades, including suitable B-flute options, can be considered where more support is required
Construction	Folding corrugated walls provide structure and resistance to everyday postal handling
Postal fit	Dimensions can be planned around the size limits of your chosen carrier or delivery service

The correct board depends on the product weight, box dimensions and amount of handling expected during transport. A small cosmetics order does not need the same construction as a box containing several books or heavy subscription products.

Letterbox and Postal-Friendly Mailers

For subscription businesses and products delivered regularly, a letterbox-friendly format can reduce the chance of missed deliveries where the product dimensions allow it.

Tell us:

• Which carrier you use
• The postal service or size bracket
• Your packed product dimensions
• The total packed weight
• Whether internal protection is required

We can then develop the box around the product and intended postal category rather than adding unnecessary height or width.

Carrier size and weight limits can change, so the final packed dimensions should always be checked against the service you intend to use before production.

Custom Printing Inside and Outside

Mailer boxes provide more printable space than many other shipping formats.

The exterior can introduce the brand when the parcel arrives, while the inside can continue the experience after the customer opens the lid.

Printing can include:

• Logos and brand colours
• Patterns and illustrations
• Product or collection names
• Handling instructions
• Social media details
• Website information
• Thank-you messages
• Promotional codes
• Reorder QR codes
• Subscription instructions
• Printed tissue or insert directions

Boxes can be printed in full CMYK colour or matched closely to supplied Pantone references. The final print method will depend on the quantity, board and design requirements.

Printing and Finishing Options

Full-Colour Printing

Full-colour printing is suitable for detailed artwork, patterns, illustrations and brands using several colours. It can be applied to the exterior or both sides of the box.

Pantone Colour Matching

Pantone references can help maintain closer consistency with an established brand palette across mailer boxes and other packaging products.

One-Colour Kraft Printing

A simple black or single-colour design on kraft board creates a clean branded look and can be suitable for businesses that prefer minimal packaging artwork.

Inside-Lid Printing

The inside lid can carry a thank-you message, product instructions, campaign information or a QR code that encourages customers to reorder.

Matt or Gloss Finish

A matt finish creates a softer, understated surface, while gloss can make selected colours appear brighter. The appropriate option depends on the board, design and level of handling expected.

Our team can recommend printing and finishing options that suit the box without adding unnecessary processes or cost.

Custom Mailer Boxes for Different Products

Mailer boxes can be developed for a wide range of businesses, including:

• Fashion and clothing brands
• Cosmetics and skincare
• Jewellery and accessories
• Candles and home fragrance
• Books and printed media
• Health and wellness products
• Gift and subscription boxes
• Craft and stationery brands
• Pet-product subscriptions
• Small electronics and accessories
• Influencer and PR packages
• Corporate welcome packs

Product weight, fragility and arrangement should be considered before choosing the board and box style. Fragile products may need inserts, dividers or additional internal protection.

Complete the Unboxing Experience

Branded Tissue Paper can be used to wrap products inside the mailer, add another brand colour or create a more considered reveal.

For larger, heavier or more transport-focused packaging, compare the available structures in our Custom Shipping Boxes range. Compact parcel formats can also be explored through Small Parcel Boxes.

The aim is to select the simplest box that provides the required protection and presentation without adding unnecessary material.

Free Design Support and Sample Approval

Send us your product dimensions, required quantity, artwork and preferred mailer style. Our team will help develop the box structure and prepare the design for production.

A free 3D mockup lets you review the artwork placement and general appearance before the physical sample is created.

You can then approve a video of the finished sample before the full order is printed. This helps confirm:

• Box dimensions
• Product fit
• Board and construction
• Closure style
• Exterior printing
• Interior printing
• Overall presentation

Order Custom Printed Mailer Boxes in the UK

Create mailer packaging that fits your products and presents your brand professionally from delivery through to unboxing.

To request a quotation, share:

• Product dimensions and weight
• Packed arrangement
• Required quantity
• Preferred box style
• Carrier or postal category
• Board and colour preference
• Outside or inside printing requirements
• Artwork and brand references

All Custom Packaging will review your requirements and recommend a suitable custom mailer-box specification.

Frequently Asked Questions

What is a custom mailer box?

A custom mailer box is a folding corrugated box made around your required dimensions and printed with your branding. It is commonly used for e-commerce orders, subscriptions, gifts and promotional products.

Can mailer boxes be printed on the inside?

Yes. Printing can be applied to the inside as well as the exterior. Internal printing is useful for branded patterns, thank-you messages, product instructions and reorder offers.

Can you make mailer boxes to my product size?

Yes. Boxes can be cut around the product or packed arrangement rather than being limited to standard stock dimensions. Share the product length, width, height and weight when requesting a quotation.

Which board is suitable for mailer boxes?

E-flute corrugated board is commonly used for lightweight and medium-sized mailers. A stronger board grade may be recommended for larger boxes or heavier products.

Do mailer boxes require packing tape?

Tab-lock and tuck-top mailers can close using their folding structure, although tape may still be recommended for some products or delivery services. Self-seal mailers include an adhesive strip for closing without separate tape.

Can you create letterbox-friendly mailer boxes?

Yes, where the product dimensions allow it. Provide your carrier, delivery service and packed product size so the box can be planned around the relevant postal limits.

Are mailer boxes supplied assembled?

Mailer boxes are normally supplied flat to reduce storage and transport space. They are creased and cut so they can be folded into shape when required.

Can inserts be added inside a mailer box?

Yes. Cardboard dividers, fitted inserts or other internal supports can be created for products that need to remain separated or securely positioned.

Can I see the design before production?

Yes. Free design support and a free 3D mockup are provided. You can also review a video of the physical sample before approving the complete production run.

How long does production take?

Production normally takes 6 to 8 business days after the final design and physical sample have been approved.

Is delivery available throughout the UK?

Yes. Completed custom mailer-box orders include free delivery throughout the United Kingdom.