Our Custom Tuck Top Mailer Boxes are designed for direct-to-consumer e-commerce shipping combining the secure closure of a tuck top with the structural strength of a mailer box. Fully custom printed inside and out, perfect for brand first unboxing experiences. Ships across the USA with low minimums.
The Custom Tuck Top Mailer Box is the ultimate direct-to-consumer packaging solution combining the brand forward design of a custom printed box with the shipping strength of a mailer. The tuck-top closure holds firm during transit, while the rigid walls protect your product from warehouse to doorstep.
Designed to replace plain brown shipping boxes, tuck top mailer boxes deliver a branded unboxing experience that surprises and delights customers the moment their order arrives. Full inside printing lets you extend your brand story inward with patterns, messages, or product photography.
Popular with subscription box companies, DTC beauty brands, apparel labels, and e-commerce businesses of all sizes, these boxes are a powerful tool for reducing returns, increasing brand loyalty, and generating social media shares.
Box Style | Tuck Top Mailer — reinforced mailer with tuck closure |
Available Sizes | Fully custom — provide L x W x H in inches |
Minimum Order Qty | 100 Boxes |
Standard Turnaround | 8–10 Business Days |
Rush Option | 4–6 Business Days |
Shipping | Free on orders over $200 (Continental USA) |
Transit Strength | Designed to withstand standard e-commerce shipping |
Digital Proof | Free — included with every order |
Primary Material | 18pt – 32pt Corrugated or Heavy SBS Cardstock |
Wall Type | Single-wall or double-wall corrugated available |
Eco Option | Recycled / FSC-Certified corrugated board |
Exterior Finish | Matte / Gloss Lamination or Uncoated Kraft |
Interior Printing | Full-color inside printing popular for DTC brands |
Special Finishes | Spot UV exterior, custom stamps, branded tape |
Structural Extras | Peel-and-seal adhesive strip, tear strip |
Sustainability | 100% recyclable, FSC and recycled options |
Yes, we offer sample kits and paid custom samples so you can verify the structure and print quality before a larger run.
Our minimum order quantity starts as low as 50 units for standard boxes, allowing you to test the market effectively.
You need a print-ready file (AI or PDF). If you don't have a designer, you can download our dielines and use Canva or Adobe Illustrator to place your logo. We review every file before printing.
Standard production takes 10-15 business days. Shipping time depends on your location and the shipping method selected at checkout.
Absolutely! We specialize in engineered custom packaging. Please fill out the custom quote form below with your specific dimensions.
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