What Are Mailer Boxes? Choose the Right Size and Style Mailer Box for Safe Delivery
Waqas Khan Pitafi 2025-07-08 13:32:42

Ensure safe delivery of your products with the perfectly sized and styled mailer boxes of your brand. Make informed decisions with the perfect mailer boxes for your brand. You might think of creating your mailer boxes with the perfect size and shape of your boxes to meet your product shipment requirements.
Read this blog to learn how to choose the right size and style of mailer box for your products.
What Are the Mailer Boxes?
Mailer boxes are the containers used to package products for transportation and shipment, and send the products to the customers safely and soundly. These boxes are produced according to the product's nature and other relevant details, like the size, shape, weight, and dimensions of the products.
Mailer boxes can be customised to meet your product packaging requirements and brand promotional elements for the overall outlook of your products and brand.
Difference Between Shipping and Mailer Boxes
Both the shipment and mailer boxes are used to transport and ship the products to the destination with due care and diligence. However, the shipping boxes are used to transport heavy and large items, while the custom mailer boxes are considered the best choice for the delivery of small and lightweight items of your brand.
Shipping boxes are primarily concerned with the protection and safe delivery of products, while mailer boxes combine different aspects of product packaging and delivery at the same time. They are equally concerned with the protection, presentation, and unboxing experience of your products and customer loyalty
Standard Mailer Box Sizes and Styles
Mailer boxes are designed to meet the product's packaging requirements and are generally produced after measuring the product's size from the inner and outer sides. However, the following are the more popularly used sizes available with the standard mailer boxes:
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Post cards
Postcard mailers are generally produced in small size 4 x 6 inches and large size 5 x 7 inches. Different other sizes might also be produced according to personalised postcard requirements.
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Letters
Letter mailer envelopes are crafted in small size 8 ½ x 11 inches and large size 11 x 17 inches. However, these sizes might be considered as the general sizes, and you can craft your personalised letter mailers to meet your brand's custom requirements.
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Mailer boxes
Small size mailer boxes are common in 12 x 12 x 12 inches, medium size 18 x 14 x 12 inches, large size 24 x 18 x 18 inches, and extra large size in 24 x 18 x 24 inches. Choose the perfect size of your product mailer boxes from the interior and exterior measurements of your mailer boxes.
How to Measure the Size of Mailer Boxes
For the measurement of the size of mailer boxes, you need to take the measurement tool, take the products, and measure the length, width, and height. The length is measured from right to left, the width from the front to the backside, and the height from top to bottom of the products.
Before you finally measure the size of the mailer boxes, you should take the measurements of the products, inside and outside size of the boxes, and an extra space for the cushioning packaging materials should also be considered. Hence, you might produce the perfect mailer box sizes for your products. This is how to choose the right size and style of mailer box for your products.
Styles and Shapes of Mailer Boxes
The shape and style of mailer boxes might also help you enhance the protection and presentation of your products and brand. You can choose the perfect styles and shapes according to the specifications of your products.
Usually, cubic or rectangular shapes one one-piece construction with roll end tuck top boxes, auto bottom boxes, and reverse tuck boxes, or rigid two-piece boxes, and many more can help boost the protection of your products.
Material Selection for Mailer Boxes
A variety of packaging materials might be used to create mailer boxes. Some of the popular choices for material selections are cardstock, cardboard, corrugated, and rigid stock. All these packaging materials are highly appealing and attractive choices for custom mailer boxes.
For the high-value, delicate, and fragile items, corrugated or rigid boxes are ideal packaging materials to improve the unboxing experience, increase the perceived value, and enhance your customers' loyalty.
Custom-Printed Mailer Boxes
Personalised mailer boxes provide you with an opportunity to stand out in your competition, delight your customers, and memorise your brand. These custom mailer boxes might encourage your customers the repeat transactions with your brand. Choose to print your personalised text with your brand image for greater visibility of your brand.
Customise your mailer packaging boxes with endless customisation options from material selection to the finishing and foiling options. These options include custom shapes, holographic foiling, coatings, PVC laminations, and embossing. You might also use different kinds of dividers, inserts, add-ons, and embellishments to delight your customer with the perfect mailer boxes.
Conclusion
After reading this blog, you are now confident to decide on your brand mailer boxes for your products. Choose a reliable custom packaging partner for your brand to boost your brand recognition and win your customers' loyalty with diligent care and protection for the resources your customers spent on the products of your brand.
You might create the perfect size, shape, and personalised text to extend and enhance the aesthetic appeal with the ideal mailer box production of your brand.
A mailer box is a self-locking cardboard or corrugated box used for shipping products. It features interlocking flaps that keep the contents secure without needing tape, making it ideal for eCommerce packaging.
Mailer boxes are strong, easy to assemble, and customizable. They offer excellent product protection, reduce shipping damage, and enhance branding through custom printing and eco-friendly materials.
Measure your product’s length, width, and height, then add 1–2 inches to each dimension to allow space for cushioning. Choosing a snug-fitting box reduces movement during transit and saves on shipping costs.
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Tuck top mailer boxes: Sleek design with front-tucking lid.
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Roll end tuck top (RETT): Extra flaps for security and strength.
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Custom die-cut mailers: Unique shapes/sizes for specific products.
Yes. Most mailer boxes are made from kraft or corrugated cardboard and are 100% recyclable, biodegradable, and reusable—especially when ordered from sustainable packaging suppliers like OXO Packaging.
Absolutely. Custom mailer boxes can include your logo, brand colors, product info, and even QR codes. This improves brand recognition and elevates the unboxing experience for customers.
Mailer boxes are self-locking and often more visually appealing—perfect for direct-to-consumer deliveries. Shipping boxes are typically larger, sealed with tape, and used for bulk or industrial shipping.
Mailer boxes are used to ship cosmetics, clothing, tech gadgets, food items, subscription kits, gifts, and small electronics. They're popular across DTC, retail, and B2B sectors.