If you run a business, whether it is small or big, how you package your products matters. It is the first thing your customers see and it speaks volumes about your brand. Custom mailer boxes can help your products stand out. But how do you create the perfect custom mailer box? Don’t worry; I will break it down for you step by step.

Step 1: Get Your Measurements Right

Before jumping into the fun design stuff, you need to figure out the basics, the size of your product and the weight. This will help you create a box that fits perfectly and protects your items during shipping.

• Measure Your Product:

Get a measuring tape and check the length, width and height of your product. But remember to leave a little extra space for padding like bubble wrap or foam, so everything stays secure.

• Consider the Weight:

Light products don’t need heavy duty materials so you can save money with thinner cardboard. But if your product is heavy you can go for thicker and stronger materials to keep it safe.

Step 2: Pick the Right Box Material

The material you choose for  your custom mailer box plays a very important role in making sure your product stays safe during shipping. Let’s look at a few options:

• Kraft Corrugated Cardboard:

This is the brown cardboard you have probably seen everywhere. It is eco-friendly, affordable and has a natural, earthy vibe. It is perfect if your brand cares about the environment.

• Un-coated White Corrugated Cardboard:

Want something clean and modern? White cardboard is a great choice. The bright surface makes your design stand out and gives your box a polished look.

• Rigid Boxes:

These are thicker and stronger than regular corrugated boxes. They are mainly used for high end products such as jewelry or electronics.

• Corrugated Cardboard:

This is the classic box material and it has layers for added strength. You can choose thicker or thinner versions depending on how heavy your product is.

Quick Tip: Look into “flute grades” (that is just the thickness of the cardboard). Lightweight items can use thinner grades like E-flute(1/16inch), while heavier ones need thicker options like B-flute(1/8inch).

Step 3: Choose How Your Box Will Close

Believe it or not, the way your box closes is a big deal. It affects how secure your package is and how easy it is for customers to open. Here are a few popular options:

• Tab-Lock Closures:

These are the most common choice for custom mailer boxes. The tabs lock into place and provide a secure seal and they don’t even need tape. They are easy to assemble and maintain.

• Dust Flaps:

If your product is delicate or you are worried about dirt. You can add dust flaps. They are a good choice because they add extra protection.

• Tear Strips:

Some boxes come with tear strips that make it very hard for anyone to open the box before it reaches the customer. This security will protect your product during shipping. 

• Custom Tape or Stickers:

For a budget friendly  way to make your packaging look more professional, you can seal it with branded tape or stickers.

Step 4: Add Your Branding

Here’s where your box really becomes your custom mailer box. Printing your logo, colors and designs on the box helps you show off your brand.Here are common printing methods:

• Flexographic Printing:

This is an affordable option and it is mostly used for simple designs. It is good if you are using only one or two colors.

• Digital Printing:

Need high quality prints in smaller batches? Digital printing is perfect for detailed designs or full color images.

• Offset Printing:

This method is super accurate and great for large orders. It is a bit more expensive but worth it if you need perfect designs.

• Foil Stamping:

Want a premium look? Foil stamping adds shiny metallic finishes (like gold or silver) to your design. It is perfect for luxury products.

Step 5: Play with Colors

Color plays a huge role in branding. The colors you choose for your custom mailer box should match your logo, website and the image of your brand. There are two main color processes to choose from:

• Pantone Matching System (PMS):

This system uses pre-mixed inks to make your colors look consistent every time. It is great for solid shades or special effects like metallics.

• CMYK (Cyan, Magenta, Yellow, Black):

CMYK uses four colors to create a wide range of shades. It is ideal for bright and vibrant images or detailed designs.

Step 6: Add Finishing Touches

The right finish can take your box from “nice” to “wow.” These extras add protection, style and personality to your packaging. Here are a few popular options:

• Aqueous Coating (AQ Finish):

A coating not only protects your box but also gives it a professional look. AQ coating is an affordable finish that provides a glossy or matte finish. Go glossy for a shiny finish or matte for something understated and chic.

• Spot UV:

Want to highlight your logo or a specific part of your design? Spot UV adds a glossy layer to certain areas, making them pop.

• Embossing/Debossing:

Embossing creates a raised design, while Debossing pushes the design inward. Both add texture and make your box feel extra special.

Step 7: Focus on the Unboxing Experience

A great unboxing experience can make your customers remember your brand and even share it online. It is all about those little details that make your packaging feel unique.

• Personal Touches:

Add a thank you note, a branded sticker or a small gift inside the box. It is a simple way to show you care.

• Stay Consistent:

Make sure the design of your custom mailer box matches with the overall vibe of your brand. Your colors, fonts and logo should match with the rest of your marketing materials to create a strong brand image.

Conclusion:

Designing custom mailer boxes is not as hard as it seems. With the right size, material and design, you can create custom mailer boxes that protect your products and impress your customers.

If you are ready to get started, check out Print24/7. They offer high quality custom printed mailing boxes according to your branding needs. Whether you are looking for eco-friendly options or luxury finishes, Print24/7 has you covered.

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