Cardboard Mailer Box

Our custom cardboard mailer boxes are the workhorse of ecommerce packaging — lightweight enough to keep shipping costs low, strong enough to protect your products in transit, and printable in full colour for a professional brand presentation. Available in any size with fast lead times and no minimum order.

• Solid board and corrugated options
• Lightweight design reduces dimensional weight charges
• Full-colour custom printing available
• Tuck-top, self-locking closure
• Recyclable, eco-friendly materials

Need heavier-duty protection? Our corrugated mailer boxes offer additional structural strength for heavier products.

The Reliable Choice for Everyday Shipping

Cardboard mailer boxes sit at the intersection of cost efficiency, practical strength, and print quality. They’re the packaging choice for brands that ship consistently, care about presentation, and understand that packaging cost per unit has a direct impact on margins at scale.

At The Mailer Boxes, we manufacture cardboard mailer boxes in solid board, lightweight corrugated, and kraft variants — each suited to different product types and shipping requirements. We’ll help you choose the right board specification so you’re not over-engineering (and overpaying) for protection you don’t need, or under-specifying and risking damage.

Board Types and Applications

Solid Bleached Board (SBB)

White on both sides, smooth, and an excellent print surface. The premium cardboard choice for products where presentation is paramount. Prints CMYK colours with exceptional sharpness. Best for lighter-weight products — cosmetics, accessories, stationery, and similar retail items.

Solid Unbleached Board (SUB)

Natural brown colour inside and out. Pairs perfectly with kraft aesthetic branding and eco-focused product ranges. Our kraft mailer boxes use this board as a foundation.

Clay-Coated News (CCN)

Recycled grey board with a white clay coating on the print face. Economical without sacrificing print quality. Widely used in mid-tier retail packaging and promotional gift boxes.

Lightweight E-Flute Corrugated

Technically corrugated, but at 1.5mm thickness it’s as lightweight as solid board while offering the fluted layer’s shock absorption. The best of both worlds for ecommerce brands shipping fragile-but-lightweight products.

Design Features That Make a Difference

A well-engineered cardboard mailer box does more than hold a product:

• Auto-lock base: Bottom folds lock in place without tape — faster packing, stronger base
• Tuck-top closure: One-handed closing, no tape required, opens cleanly for customers
• Perforated tear strip: Accessible entry without scissors or tools — reduces frustration and box damage
• Retuck feature: Allows resealing after first open — supports return shipping and reuse

Frequently Asked Questions

What’s the difference between a cardboard mailer box and a corrugated mailer box?

Cardboard (solid board) is a dense, single-layer sheet material. Corrugated has an inner fluted layer sandwiched between two liners. Corrugated is generally stronger for heavier products; solid board prints more crisply and is better for lighter items. See our comparison between cardboard mailer boxes and corrugated mailer boxes if you’re unsure which is right for your product.

Can I get a plain (unprinted) cardboard mailer box?

Yes. Plain white or kraft cardboard mailer boxes are available in standard sizes. See our plain mailer boxes range for stock options.

How much does custom printing add to the cost?

Custom printing costs depend on quantity, colour coverage, and finish. One-colour printing on a kraft exterior is the most economical option; full-colour with laminate finish on white board costs more. Request a quote with your specifications for accurate pricing.

Cardboard Mailer Boxes That Work as Hard as You Do

Reliable, printable, and cost-effective. Request a quote for your custom cardboard mailer boxes and our team will help you find the right spec for your products and budget.