Made-to-order packaging
Custom Printed Corrugated Mailer Box
A hinged corrugated mailer with locking tabs and configurable exterior artwork.
Share product dimensions, packed weight, order quantity, delivery route, and artwork goals for a tailored mailer recommendation.
Key Parameters
Engineering parameters for this format.
Typical ranges from our production floor. Your dimensions, board combination and print are confirmed in the quotation.
| Board construction | Corrugated board, single-wall; kraft, white-top or fully bleached liner |
|---|---|
| Flute options | E-flute ≈1.5 mm for retail surfaces; B-flute ≈3.0 mm for heavier packed loads |
| Liner weights | 125–250 gsm liners; combined board 500–850 gsm equivalent |
| Size range | Custom internal dimensions; typical L 150–600 mm, W 100–450 mm, D 30–200 mm |
| Printing | Offset (sheet-fed) for fine artwork; flexo for simpler coverage on kraft |
| Color capability | 4-color CMYK process plus 1–2 spot/Pantone colors; inside printing available |
| Surface finishes | Matte / gloss lamination, spot UV, aqueous coating, hot-foil logo |
| Typical MOQ | 1,000–3,000 pcs per design (typical band, confirmed against size and print in the quotation) |
| Sampling | Blank structural sample 3–5 days; printed sample 5–8 days after artwork |
| Bulk lead time | 12–18 days after sample approval and deposit (typical band, confirmed against size and print in the quotation) |
| Delivery format | Shipped flat, folded at the side seams; packing in export master cartons |
Print & Finishing Workflow
How your box is printed, finished and checked.
The in-house sequence this format runs through — from prepress to the final inspection before packing.
- 01
Prepress & dieline
Your artwork is positioned on the confirmed mailer dieline; panel orientation, barcode zones and fold clearances are checked before plates are made.
- 02
Lamination & print
White-top liners are offset-printed CMYK with spot-color control; linen-textured or kraft liners can be printed flexographically for a natural look.
- 03
Color control
Press sheets are compared against your approved reference under D50 lighting; Pantone draws are matched within ΔE tolerance agreed in the order.
- 04
Finishing
Matte or gloss lamination, spot UV logos, hot-foil stamping and aqueous coating are applied before die-cutting.
- 05
Die-cut, fold & QC
Sheets are die-cut, glued at the side seams, folded flat and inspected for tab fit, glue strength and print defects before packing.
Customization Capability
Built around your product, not off the shelf.
Every parameter above can be specified. These are the dimensions of customization this format supports best.
Structure & dimensions
Internal dimensions, lid depth and tab geometry are engineered from your packed product, with allowance for inserts and loading.
Board & color
Kraft, white or full bleached liners in E- or B-flute balance print quality against stacking strength for your route.
Full-color print
CMYK + Pantone outside, and optional inside printing for a branded reveal when the lid opens.
Finishes
Matte, gloss, spot UV and foil are combined on the same sheet to separate logo areas from photography.
Inserts & packing
Paperboard or corrugated inserts, tissue, and export packing are specified together with the box.
Application context
Where this format can begin.
- Direct-to-customer orders
- Retail product kits
- Branded launch packages
Structure
Define the opening, loading and closure.
A one-piece die-cut mailer with an attached lid, front roll-over panel, and side locking tabs.
Set the internal dimensions and tab geometry around the packed product and opening sequence.
Material & board
Review construction against the packed product.
- Kraft Corrugated Board
- White Corrugated Board
- E-Flute
- B-Flute
Compare kraft or white corrugated board and E- or B-flute against presentation and handling needs.
Printing & surface
Place artwork on the confirmed dieline.
- Flexographic Printing
- Offset Printing
Choose flexographic or offset printing according to artwork detail, coverage, and production plan.
Features
Add only what supports use and packing.
- Locking Tabs
Tune locking tabs for convenient assembly and a clean front edge.
Inserts & accessories
Plan product organization with the outer box.
An insert is optional and should be assessed from the product arrangement and handling brief.
If internal support is needed, prototype it with the complete product, accessories and practical finger clearance.
Sampling
Use the sample that answers the current question.
A material reference helps compare surfaces, a blank structural sample checks fit and assembly, and a printed sample reviews the combined structure and artwork. Scope, cost and timing are confirmed before preparation.
Review sampling options →Factory reassurance
One working specification from review to production.
Final dimensions, material, artwork version, quantity, sample approval and packing instructions are recorded for the production discussion. Manufacturing feasibility, schedule and commercial terms remain subject to quotation confirmation.
Learn about the factory →Related products
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Discuss Custom Printed Corrugated Mailer Box
Share product dimensions, packed weight, order quantity, delivery route, and artwork goals for a tailored mailer recommendation.
Request a custom quote →