Hale Path Packaging makes custom mailer boxes from printed corrugated board for USA ecommerce, subscription and retail brands. Each box is made to your dimensions, closes without tape, and can be printed on the outside, the inside or both. Choose your paper stock, print method, finish and an optional cardboard insert, then send us your product size and quantity for a quote.
A mailer box is a shipping box and a retail box in one. It protects the product on the way out and makes the opening feel intentional. Here is what you get:
Our mailer boxes are built from printed corrugated board, and you can choose kraft paper, art paper, card stock or recycled paper for the printed surface. Kraft gives a natural, earthy look and suits handmade and wellness brands. Art paper gives the smoothest surface for full-color artwork. Recycled paper is the choice if sustainability is part of your story; you can also browse our eco-friendly mailer boxes.
We print with offset, digital, UV and screen printing. In short: offset is the usual pick for larger runs and consistent color, digital suits shorter runs and detailed artwork, and UV and screen printing add punch for logos and special effects. Not sure which to pick? Tell us your artwork and quantity and we will recommend one. You can print the outside only, or the inside and outside.
Matte lamination gives a calm, modern look. Gloss lamination makes colors pop. Soft touch feels smooth and premium in the hand, and UV coating adds shine and helps resist scuffs. For extra detail you can add embossing, debossing or foil stamping to your logo.
The flute is the wavy layer inside corrugated board. E-flute (about 1/16 inch) is thin and smooth, so it prints sharply and suits lighter items such as cosmetics, accessories and small electronics. B-flute (about 1/8 inch) is thicker and cushions better, which makes it a good fit for heavier or more fragile products. Tell us what you are shipping and we will point you to the right one.
Many brands pick a box color before they finalize artwork. A black mailer box gives a premium look, a white mailer box keeps branding clean, a natural kraft mailer suits earthy and handmade products, and full-color artwork turns the box into a brand statement. Tell us your color preference and quantity and we will confirm what is available for your order.
Sizing is the step that most affects fit and shipping cost. Do it in three steps:
Carriers price packages by the space they occupy as well as by weight (dimensional weight), so a snug box can cost less to ship than an oversized one. Custom box sizes can be made to your product dimensions. If you are unsure, send your measurements through our contact page and we will check them.
Fragile products need to stay in place. Pair your mailer with a cut-to-fit cardboard insert to hold bottles, jars, palettes or tubes. Browse our protective inserts and dividers, or tell us your product size and we will suggest a layout.
Get Custom Quote
To get an accurate quote, send us: product dimensions (L x W x D in inches), estimated quantity, preferred paper stock and flute, print method and number of colors, finish, insert requirements, and your artwork or a reference design.
Request a quote for your custom mailer boxes with logo, or ask about wholesale quantities.
Get Custom Quote
Excellent services! They helped choose the right size, finish, and window shape. The boxes fit our brand, and the minimum order quantity was reasonable for business.
They helped us pick the right size, finish, and custom window shape. The boxes fit our brand perfectly, and the minimum order quantity was reasonable.
We wanted luxury but eco-friendly. They suggested recyclable rigid boxes with a frosted window and satin insert. Customers now post unboxing videos; that’s how good they look.
We needed custom boxes with a logo and food-safe window for our Eid cookies. They guided us on materials and delivered exactly what we wanted. Clients love the unboxing.
Highly satisfied with Hale Path Packaging. Their packaging solutions were premium, printing was vibrant, and their high quality and customer happiness made them a trusted partner.
Hale Path Packaging delivered unique packaging products. The boxes were sturdy, printing was vibrant, and their attention to detail ensured products looked premium in the market
They provided reliable and high-quality packaging solutions. The boxes and pouches were well-designed, printed perfectly, and delivered on schedule with excellent customer support throughout for brands.
Hale Path Packaging impressed us with their boxes and pouches. The printing was perfect, materials were durable, and their team handled everything efficiently with excellent service.
Outstanding experience with Hale Path Packaging. Their packaging solutions were durable, beautifully printed, and delivered on time. The team was responsive and ensured a happy order.
Hale Path Packaging delivered high-quality packaging materials with perfect printing. Their attention to detail and deadlines made them a trustworthy partner. Our customer was really satisfied.
A mailer box is a shipping box and a retail box in one. It closes without tape, can be printed inside and out, and gives customers a branded unboxing. A regular shipping box is usually plain and made for transit only.
The quantities shown on this page start at 10,000 units. If you need a smaller run, send us your size and quantity through the quote form and we will tell you what is possible.
Yes. Choose outside only or inside and outside when you build your quote. Many brands print the logo outside and put a thank-you message, a discount code or a QR code on the inside lid.
Offset is the usual choice for larger runs and consistent color. Digital works well for shorter runs and detailed artwork. UV and screen printing add special effects. Send us your artwork and quantity and we will recommend one.
Stack your product as it will ship, measure the inside stack as length x width x depth in inches, and add about 0.25 inch to each dimension.
Yes. For fragile items such as glass bottles, jars or cosmetics we can add a cut-to-fit cardboard insert. Mention it in your quote request with your product size.
Submit your size, quantity and artwork, review the details with our team, approve the order, and we produce and ship it.
Yes, we ship anywhere in the USA, including California. See our shipping policy for details.
The price depends on five things: box size, paper stock, number of print colors, finish and quantity. Because every order is built to your specification, the quickest way to get an exact number is to build your quote on this page or send us your size and quantity.
Three changes make the biggest difference. Order a higher quantity, because the setup cost is spread over more boxes. Use fewer print colors or print the outside only. And choose a simpler finish, such as matte lamination instead of foil stamping. If you are searching for cheap custom mailer boxes, tell us your budget and we will suggest a setup that fits it without hurting protection.
The standard sizes shown on this page are 5 x 4 x 1 and 6 x 5 x 2 inches. For anything else, choose a custom size in the quote form and enter your own Length x Width x Depth. You can enter inches, centimeters or millimeters.
Matte lamination has a flat, modern look and hides fingerprints. Gloss lamination is shiny and makes colors look brighter. Soft touch has a velvety feel that customers notice the moment they pick up the box. UV coating adds shine and helps protect against scuffs.
Upload your artwork with the quote form. Vector files such as AI or PDF give the sharpest print, but if you only have a logo image, send it anyway and our team will tell you whether it needs to be improved before printing.
E-flute (about 1/16 inch) is thin and smooth, prints sharply and suits lighter items. B-flute (about 1/8 inch) is thicker and cushions better for heavier or more fragile products.
