Custom Cardboard Boxes

Custom Mailer Boxes

Sturdy, self-locking mailer boxes printed with your artwork. Designed for e-commerce, subscription services, and retail shipping across Australia.

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    Features

    Full Colour Mailer Boxes Built for Your Brand

    01

    Vivid Full Colour Printing

    Your brand artwork is printed in full CMYK colour across the entire exterior of the box. Sharp detail and consistent colour reproduction ensure your packaging looks professional on every unit.

    02

    Custom Sizes Available

    Every mailer box is manufactured to your exact dimensions. Whether you need a compact box for jewellery or a large format for clothing, we build it to fit your product perfectly.

    03

    Eco-Friendly Materials

    Choose from kraft or recycled cardboard options for a lower environmental footprint. Both materials are recyclable and well suited to brands that prioritise sustainability.

    04

    Premium Finish Options

    Elevate your packaging with matte lamination, gloss lamination, spot UV, or foil stamping. These finishes add a tactile quality that makes your unboxing experience memorable.

    05

    Perfect for E-Commerce

    Self-locking tabs mean no tape or glue is needed during assembly. The tuck-front design provides a clean unboxing moment for subscription boxes, online retail, and direct-to-consumer brands.

    06

    Fast 8-10 Day Turnaround

    Production takes 8 to 10 business days after proof approval. We keep you updated throughout the process so you always know when to expect delivery.

    07

    Low Minimum Orders

    Our minimum order quantities are flexible. We recommend starting at 100 units, which keeps per-unit costs reasonable without requiring a large upfront investment.

    08

    Free Australia-Wide Shipping

    Every order ships free to any address within Australia. Delivery typically takes 3 to 5 business days after dispatch, so your packaging arrives quickly.

    09

    Self-Locking Assembly

    The self-locking base and tuck-front closure make assembly fast and straightforward. No additional adhesive is required, saving time in your fulfilment workflow.

    Custom Mailer Boxes for Australian Brands

    Custom mailer boxes are one of the most popular packaging formats for e-commerce, subscription services, and direct-to-consumer retail. Their self-locking construction eliminates the need for tape or glue, making them quick to assemble and easy to open. For Australian brands shipping products nationwide, mailer boxes combine practical protection with a polished, branded presentation that customers remember.

    Whether you sell skincare, apparel, food products, or gifts, a custom mailer box turns every delivery into a brand experience. The flat exterior panels provide ample space for full-colour printing, allowing you to showcase your logo, brand colours, and product messaging on every surface. Many of our clients pair mailer boxes with custom product sleeves to add an extra layer of branding inside the box.

    Mailer boxes are also a practical choice for businesses that need packaging to perform double duty. The corrugated board construction protects items during transit, while the printed exterior means your box is shelf-ready when it arrives. For brands looking for a versatile format that works across multiple product lines, custom mailer boxes offer exceptional flexibility.

    Design and Customisation Options

    Every mailer box we produce is fully customised to your specifications. You choose the dimensions, the artwork, and the finish. We provide a dieline template based on your measurements so your designer can place artwork precisely where it needs to go. If you do not have a designer, our team can assist with layout and file preparation.

    Popular design choices include printing on both the exterior and interior of the box. An interior print adds a surprise element to the unboxing experience and is particularly effective for subscription boxes and gift packaging. You can also add finishing touches such as spot UV on your logo, foil stamping for metallic accents, or matte lamination for a soft, premium feel.

    If your brand uses eco-friendly positioning, a natural kraft exterior with a simple one-colour print creates a clean, sustainable look. Many Australian brands in the handmade soap and candle markets use this approach to align their packaging with their brand values.

    Materials and Printing Quality

    We manufacture mailer boxes from corrugated board, which provides excellent structural strength for shipping. The fluted inner layer absorbs impact during transit, protecting your products from damage. For lighter items, a standard cardboard construction may be more cost-effective while still delivering a high-quality printed finish.

    All printing is done using offset methods, which produce sharp, vibrant colour across the entire run. Offset printing is the industry standard for custom packaging because it delivers consistent results whether you order 100 or 10,000 units. Colour matching is handled at the proof stage, so you can review and approve your artwork before production begins.

    Kraft board is also available for brands that want a natural, unbleached look. Kraft mailer boxes are fully recyclable and pair well with water-based print finishes for a clean, eco-conscious presentation.

    Ordering and Delivery

    To get started, fill out our quote request form with your box dimensions, quantity, and any finishing requirements. We respond within one business day with pricing and a production timeline. Once you approve the quote and submit payment, we send a digital proof for your sign-off before printing begins.

    Production takes 8 to 10 business days from proof approval. Shipping is free on all orders within Australia, with delivery in 3 to 5 business days after dispatch. If you need your custom product boxes sooner, contact us to discuss expedited options.

    FAQ

    Have a question?

    Browse the answers below, or get in touch and we will be happy to help.

    How do I order a sample of a custom mailer box?

    Every order includes a free digital proof and mockup so you can see exactly how your mailer box will look. Physical samples are available on request, with a sampling fee that depends on the complexity of your order.

    What is the turnaround time for custom mailer boxes?

    Standard production takes 8 to 10 business days after your proof is approved. Delivery within Australia takes an additional 3 to 5 business days. Rush production plans are also available for tighter deadlines.

    What is the minimum order quantity?

    Our minimum order quantities are flexible. We recommend starting at 100 units, which provides a good per-unit cost without a large upfront commitment.

    How do I get pricing for custom mailer boxes?

    Fill out our quote request form or email us with your box dimensions, quantity, and finishing preferences. We typically respond within one business day.

    What sizes are available for mailer boxes?

    All our mailer boxes are made to your exact dimensions. There is no standard size you need to conform to. Just provide your measurements and we manufacture to suit.

    Can I print on the inside of the mailer box?

    Yes. Interior printing is a popular option for subscription boxes and gift packaging. It adds a branded surprise element when the customer opens the box. Many brands pair interior prints with custom product sleeves for a layered unboxing experience.

    Testimonials

    What our customers say

    4.9 from 53+ reviews

    Brilliant experience from start to finish

    “I'd been searching for a packaging supplier for my new skincare line and Custom Cardboard Boxes absolutely delivered. Sophie walked me through the whole process, from choosing the right box style to finalising the artwork. She was incredibly patient when I kept changing my mind on colours and never once made me feel like a hassle. The finished product looks unreal. The print quality is spot on and my customers have been commenting on how premium everything looks. Couldn't recommend them more highly.”

    T

    Tegan O'Sullivan

    Top-notch custom mailer boxes for our coffee brand

    “We've just received our first order of custom mailer boxes and honestly, they've exceeded all expectations. Working with Ethan was an absolute pleasure. He was super responsive, always kept us in the loop, and even suggested a few tweaks to our design that made the final product look way more professional. The turnaround time was faster than we expected and the pricing was very competitive. We'll definitely be ordering again for our next roast release.”

    J

    Jarrod McLeod

    Charlotte was absolutely fantastic

    “Charlotte was absolutely fantastic to work with. As a small business owner just starting out with handmade candles, I had no idea what I needed in terms of packaging. She took the time to explain all the different options, helped me pick the right size and material, and the design team nailed my artwork on the first go. The boxes arrived in perfect condition and they look gorgeous. My brand feels so much more legit now. Thank you, Charlotte!”

    M

    Mia Chen

    Exceptional quality and service, highly recommend

    “We've been working with Custom Cardboard Boxes since we launched our botanical skincare range and they've been nothing short of brilliant. Liz has been our main contact and she's always gone above and beyond to make sure everything is sorted. The print quality on our boxes is crisp, the colours are bang on, and the packaging feels really sturdy and premium. We've tried other suppliers before but none have come close to the level of service and quality we get here. Will not be going anywhere else.”

    W

    Wild Honey Botanicals

    Great product, slight delay on shipping

    “The boxes themselves are fantastic. Really well made, colours came out perfectly, and the design team were really helpful during the proofing stage. Tom was great to deal with and answered all my questions promptly. Shipping took a touch longer than originally quoted, but I understand these things happen and the end result was well worth the wait. Overall a really positive experience and I'd still recommend them to anyone looking for custom packaging.”

    B

    Ben Kirkpatrick

    Made my small business look like a big brand

    “I recently launched my first range of protein bars and needed packaging that would really stand out on shelves. Michael was so helpful and patient as we worked through different design concepts and box styles. He even helped me adjust my artwork to make sure the print came out perfectly. When the boxes arrived, I was absolutely stoked. They look incredibly professional and the quality is outstanding. Custom Cardboard Boxes has genuinely taken my brand to the next level. Can't thank them enough.”

    P

    Priya Naidoo

    Perfect custom belly bands for our soap range

    “We ordered custom belly bands for our artisan soap range and they turned out beautifully. Amie was our point of contact and she was lovely to deal with. Really communicative and made the whole process dead easy. The print quality is crisp, the fit around our bars is spot on, and they've given our products such a polished, professional look. The pricing was also very reasonable compared to what we were quoted elsewhere. Already planning our next order!”

    S

    Samantha Russo

    Fast turnaround and outstanding results

    “We needed custom packaging for a product launch and were working to a really tight deadline. Eric was brilliant. He got everything sorted quickly and kept me updated every step of the way. The auto-lock boxes we ordered are sturdy, the print is sharp, and the whole unboxing experience looks premium. I was genuinely impressed by how fast they turned everything around without compromising on quality. Will absolutely be using Custom Cardboard Boxes for all our future orders.”

    D

    Daniel Whitmore

    Excellent service, Kevin was a legend

    “This was our first time ordering custom packaging and we were a bit nervous about the whole process. Kevin put us at ease straight away. He was super communicative, explained everything clearly, and made brilliant suggestions that improved our original design. The finished boxes look absolutely mint and arrived right on schedule. Our customers have already been raving about the packaging. Honestly couldn't have asked for a better experience. Cheers, Kevin!”

    K

    K. Nguyen

    Really happy with the end result

    “Ordered custom gift boxes for my online boutique and the quality is lovely. The cardboard is thick and sturdy, the printing is sharp, and the colours match my branding perfectly. Davis was my main contact and he was really easy to work with. Always quick to reply and happy to help with any changes. The only minor thing was a small delay getting the initial proof back, but once that was sorted everything moved along smoothly. Would happily order from Custom Cardboard Boxes again.”

    O

    Olivia Hart