Custom Mailer Boxes

SKU: CUSTOM-MAILER-BOXESNext Business Day Printing Options Available

Yes. Selected standard sizes and specifications are available with Same Day Printing, while other configurations are available with Next Business Day or longer production schedules. Turnaround depends on your chosen size, quantity, artwork approval and finishing requirements. 

We have no minimum order quantity. Whether you need a single prototype or thousands of printed mailer boxes, we can produce quantities to suit your project. Keep in mind that ordering multiple boxes is much more cost-effective than purchasing individual units. 

Yes. We regularly help businesses design and produce prototypes for custom packaging, mailer boxes and point of sale displays. Prototyping allows you to assess the size, fit, presentation and functionality before committing to a larger production run. Speak with our team about your project and we’ll confirm whether our prototyping solutions are suitable for your application. 

Measure the product you intend to pack, then allow additional space for protective packaging such as tissue paper, honeycomb wrap or bubble wrap. Choosing a box that’s too large can increase freight costs, while one that’s too small may not adequately protect your product. 

Internal dimensions describe the usable space inside the box and should always be used when selecting a size. External dimensions include the thickness of the corrugated board and folded construction, making the finished box slightly larger than its internal measurements. 

E-Flute (approximately 1.6mm thick) produces a slimmer box with an excellent print surface, making it ideal for lightweight products such as cosmetics, apparel and promotional items.

B-Flute (approximately 3mm thick) provides greater strength and rigidity for heavier products including books, bottles and gift packs.

There is no single weight rating that applies to every mailer box. Performance varies depending on the box dimensions, the product being shipped, protective packaging, transport methods and handling throughout the supply chain. We’re happy to share how different constructions are commonly used, however we recommend testing your packaging with your actual products before proceeding with production. 

Yes. Full-colour printing is available on the outside, inside or both sides of your mailer box. Interior printing is a popular option for thank you messages, promotional artwork and creating a premium unboxing experience. 

Digital screens display colour using RGB, while printed packaging uses CMYK inks. Colour variation is normal. For the most accurate results, artwork should be supplied in CMYK. Colours printed on kraft board will appear more muted than those printed on white board.

Vector PDF files are preferred, although Adobe Illustrator files are also accepted. Images should be supplied at 300dpi at final size, and all fonts should be outlined or embedded. Visit our Artwork Guidelines for full specifications. 

Mailer boxes feature an interlocking design that assembles without glue or tape. For parcels travelling through courier or postal networks, we recommend sealing the front flap with a strong branded sticker or shipping tape for added security. 

All mailer boxes are supplied flat-packed to reduce shipping costs and storage space. They are pre-creased and designed for quick hand assembly without specialist equipment. 

Yes. Mailer boxes are commonly used for Australia Post, courier networks and third-party fulfilment providers. Choosing the correct size can help reduce dimensional shipping costs. If you will be posting directly without putting it in a bag, when designing your box think about where the shipping label will sit – you can event incorporate this into the design so it looks intentional.  

Yes. Our corrugated mailer boxes are recyclable through standard paper and cardboard recycling streams. We recommend removing any non-paper components, you  may have added such as plastic tape, before recycling. 

Mailer boxes are suitable for transporting packaged food products such as sealed coffee bags, wrapped confectionery and boxed products. They are not intended for direct contact with unwrapped food unless an appropriate food-safe liner or packaging barrier is used. 

Unlike many packaging suppliers, our mailer boxes are digitally cut, so you aren’t restricted to a library of existing die sizes. In most cases, pricing is based on the overall size of the box, not whether it’s a standard or custom dimension.

This gives you the flexibility to choose from our popular standard sizes or create packaging that’s tailored to your product without the traditional tooling costs associated with custom packaging.

Yes. Whether you have finished artwork or just an idea, our team can assist with artwork setup, layout and preparing your design for print. 

Many customers also order matching product labels, stickers, belly bands, box sleeves, printed inserts, vouchers and thank you cards to create a consistent branded packaging experience. 

We have a dedicated customer service team that can assist you through call, email, or chat. Please do not hesitate to call us at 1300 663 242 or email us at helpme@samedayprinting.com.au.