Custom Mailer Boxes Manufactured for Your Brand
Elevate your unboxing experience with durable, high-end custom mailer boxes. From subscription boxes to eco-friendly e-commerce shippers, we provide crush-resistant corrugated packaging designed to protect your products and promote your brand. Enjoy wholesale factory pricing and free shipping nationwide.
Subscription & E-commerce Mailer Boxes
Ensure your products arrive safely and in style. Our mailer boxes feature interlocking tabs and reinforced walls, perfect for transit without the need for excessive external tape. Choose from a variety of styles tailored for your specific shipping needs.
Advanced Manufacturing Standards for Custom Mailers
At Rush Custom Boxes, we produce more than just shipping containers; we engineer branded assets. Our mailer boxes are manufactured in our US-based facilities, utilizing heavy-duty E-flute or B-flute corrugated cardboard to ensure your products survive the rigors of the postal system while maintaining a high-end look.
Technical Specifications for Mailer Box Stocks
| Stock Material | Best Use Case | Flute Thickness | Weight Support | Sustainability |
|---|---|---|---|---|
| White Corrugated | Vibrant Retail Branding | 1/16" (E-Flute) | High (Up to 10 lbs) | Fully Recyclable |
| Natural Kraft | Eco-Friendly / Organic Brands | 1/16" or 1/8" | Heavy-Duty | 100% Compostable |
| Luxury Rigid Mailer | Jewelry & Premium Gifts | High-Density Board | Premium Protection | FSC Certified |
High-Fidelity CMYK & PMS Printing
We leverage advanced offset and digital printing to ensure your brand colors are rendered with 100% accuracy. From inside-only prints to full-bleed exterior graphics, our G7-certified processes deliver smudge-free, professional results.
Structural Integrity & Easy Assembly
Our mailers are designed for efficiency. Most styles feature "pop-and-lock" or "front-tuck" designs that allow your team to assemble and pack orders in seconds, reducing fulfillment labor costs.
Premium Finishing & Protective Coatings
Add a layer of sophistication with matte, gloss, or soft-touch lamination. We also offer aqueous coatings that protect your print from moisture and scuffing during long-distance shipping.
Sustainable Sourcing & Low Carbon Footprint
We prioritize the environment by using recycled materials and soy-based inks. By operating production hubs in Washington and California, we minimize transit emissions for our domestic clients.
The RCB Mailer Quality Guarantee
Partnering with a direct manufacturer ensures you receive consistent quality across every wholesale order. Our specialized quality control includes:
- Crush-test verification to ensure transit safety.
- Edge-to-edge color consistency across large production runs.
- Precision die-cutting for tight-sealing tabs and dust flaps.
- Food-grade, non-toxic materials for sensitive product packaging.
- Direct support from packaging experts in our US facilities.
Get a Wholesale Quote for Custom Mailers
Submit your project details below and receive a personalized quote within 3 hours. Our experts are ready to help you optimize your box dimensions and material choice for maximum savings.
Complimentary Design & Die-Line Support
Don’t have a print-ready file? No problem. Our in-house graphic designers provide free 2D and 3D digital mockups with every order to ensure your logo and graphics sit perfectly on your custom mailer boxes.
Frequently Asked Questions About Custom Mailer Boxes
Get quick answers regarding lead times, material durability, and wholesale ordering for your shipping boxes.
What is the MOQ for custom mailer boxes?
We support small businesses with low minimums starting at just 100 units. For larger wholesale orders, we offer tiered discounts that significantly reduce the unit price.
Are your mailer boxes strong enough for international shipping?
Yes, our E-flute and B-flute corrugated cardboard is specifically selected for its crush-resistance. Our boxes are built to handle the rigors of multi-stage shipping journeys without collapsing.
How fast is the turnaround time for a custom order?
Our standard production time is 8–10 business days after design approval. Because we manufacture domestically in the USA, we avoid the lengthy delays often seen with overseas suppliers.
Can I print on the inside of the box?
Absolutely. We offer double-sided printing, allowing you to surprise your customers with a custom message or vibrant pattern on the interior of the lid and walls.
What is the difference between E-flute and B-flute?
E-flute is thinner (1/16") and provides a smoother surface for high-quality printing, best for retail and subscription boxes. B-flute is thicker (1/8") and offers more cushioning for heavier or more fragile items.
Do you offer eco-friendly or plastic-free options?
Yes, all our corrugated mailer boxes are made from recyclable materials. We also offer natural Kraft stock which is 100% compostable and uses water-based or soy-based inks.
Can I get a custom size for my box?
Yes, we provide fully bespoke sizing. You are not limited to stock sizes; we can create a custom die-line specifically for the dimensions of your product to ensure a snug, secure fit.
How do I ensure the print doesn't scratch during shipping?
We suggest adding a matte or gloss lamination for mailers. This plastic-free protective layer acts as a shield against the scuffs and scratches that naturally occur during sorting and transit.
How do I qualify for Free Shipping?
All orders shipped within the Continental USA qualify for free shipping. There are no hidden fees or surcharges; the price you are quoted is the final landed price at your doorstep.
What file format do you need for my artwork?
We recommend vector files in AI, PDF, or EPS format. This ensures that your branding remains crisp and professional when scaled to the size of your mailer box.
Visit our dedicated FAQ center for more information on materials, design specs, and shipping policies. View the Full FAQ →
Request a Custom Quote
Get custom quotes, helpful design support, and dependable production that fits your business needs. We make ordering custom products simple, affordable, and professional.
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