How to Design Custom Mailer Boxes for Faster Shipping & Lower Costs?

Emenac Packaging USA
2025-11-20
How to Design Custom Mailer Boxes for Faster Shipping & Lower Costs?

Shipping delays and higher costs can eat into your profits, leaving customers unhappy and dissatisfied. In addition, it would damage the brand’s reputation.

That’s why the right packaging box, size, and design help a lot in rapid shipping and minimum shipping costs. Most brands overlook custom mailer boxes, but they do not have an idea how these boxes would help their brand win over competitors.

This blog post provides all the information on designing custom-printed mailer boxes for effortless delivery.

Understanding the Right Design of Custom Mailer Boxes

Custom mailer box packaging can make shipping faster and lower shipping costs. But without the right size and design, it might create hurdles in shipping, so understanding the right size and design is crucial.

Most of the shipping carriers charge for dimensional weight pricing rather than only charging for actual weight. This means if your mailer box is too big for what’s inside, you are ultimately paying for empty air.

Here are some tips to design the right type of custom mailer box.

Choose the Right Size

When you don’t want to pay for extra shipping costs, it is a must to choose the right-sized shipping box. Choose a size that best fits without leaving empty space. Make measurements carefully and leave half or one inch space on each side for minimal cushioning.

Choose the Right Materials

Not all types of mailer boxes are created equal. You can use single-wall corrugated cardboard for lightweight items, and it’s cost-effective than double-wall material. Double-wall boxes are an ideal option for heavyweight items.

Before choosing the right material, contact your packaging supplier to come up with the right options that work best for your product and branding. Do not commit one mistake various times.

Accurate Design

Time is money, and it shouldn’t be wasted at any cost. For example, a box that takes 1 minute extra to assemble might not feel you much, but when you multiply that by hundreds of orders and you will pay more for extra labor hours.

If we consider design, then we think self-locking mailer boxes are the best option because they can be assembled in few time. They might cost more compared to traditional packaging boxes, but you can save a lot in packing time and labor expense.

Built-in Protection

Smart and minimal packaging design cuts packaging material costs. Corner protectors, internal flaps, and crush-resistant features provide better protection without incurring extra costs in which you might pay more.

Strong-fitting compartments are ideal for delicate items where a fear of breakage or damage is concerned. Do not ship delicate products without cushioning features because it will cost you in several ways.

How Many Customization Choices are Available?

Customization doesn’t mean to be expensive. If your budget is tight, you still can make a bigger impact with a few customizations.

To create a memorable unboxing experience, you can print on the inside instead of outside printing. Try considering using two or a combination of three colours rather than sticking to only one.

If your budget allows you to invest more, you can go for outside printing too. Use a simple design with solid colors and avoid using complex or expensive photos or graphics.

The Bottom Line!

There is no rocket science to designing those custom mailer boxes that reduce shipping costs and ensure faster shipping.

It only requires thoughtful planning, which we showed in front of you through this blog post. The extra money you save on shipping will benefit you in multiple ways.

One other thing that matters is choosing the right packaging supplier, like Emenac Packaging USA. We know how to manufacture well-designed customized mailer boxes that not only ensure safe shipping but also reduce shipping costs.

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Author : Emenac Packaging USA

Having an ability to customize packaging boxes in different sizes, shapes and styles, Emenac Packaging fulfills the requirement of customers in lowest rate with flawless printed results. Not only we accept short and long run orders, we also use high quality Cardboard, Kraft and Corrugated materials to give you unrivaled printing and packaging solutions.

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