Custom subscription and e-commerce boxes built for the doorstep.
Printed mailers that survive carrier networks, sized to avoid paying for air, and designed so the moment of opening feels like part of the product.
- Sized to beat dimensional-weight pricing
- Inside print and custom inserts
- Crush-tested E- and B-flute options
- Minimum
- 50 units
- DIM divisor (all carriers)
- 139
- Inside print
- 4/4
- Style
- Roll-end tuck front
- Board
- E-flute, white
- Outside + inside
- Insert
- Card divider
Why box size now matters more than ever.
Parcel carriers charge for the bigger of the actual weight and the dimensional (DIM) weight — length × width × height in inches, divided by a divisor. UPS and FedEx use a divisor of 139 for daily rates, apply it to packages of any size and round each dimension up to the next whole inch. On July 12, 2026, USPS adopted the same 139 divisor and whole-inch rounding for parcels over one cubic foot (1,728 cubic inches) on Priority Mail, Ground Advantage and Parcel Select.
Example with UPS or FedEx: a 12.2 × 10.8 × 6.1 inch box is billed as 13 × 11 × 7 = 1,001 cubic inches, which at 139 is about 7.2 lb of DIM weight — even if the contents weigh 2 lb. Trimming the box to exactly 12 × 10 × 6 (720 in³) brings that to about 5.2 lb, two weight brackets lower.
Custom-sized mailers are often the fastest payback in e-commerce packaging. Send us your product mix and current box, and we’ll suggest sizes that sit just inside a pricing threshold.
E-commerce mailer options.
| Styles | Mailer boxes (roll-end tuck front, tuck top), shipping boxes (RSC), sleeve over mailer |
|---|---|
| Board | E-flute for most mailers; B-flute or 32–44 ECT for heavier or fragile goods; see corrugated boxes |
| Outside, inside or both; 1-color inside message is the budget favorite | |
| Inserts | Card dividers, corrugated cradles, product cut-outs |
| Features | Tear strips, double adhesive strips for returns, die-cut handles |
| Testing | Designs can be drop-tested to ISTA 3A or Amazon ISTA-6 profiles on request |
Designing the subscription unboxing.
Subscription customers judge the whole box every month, and many film it. A few things that consistently work:
- A reveal sequence. Branded outside → a message or pattern inside the lid → products arranged in an insert → an insert card that explains this month’s theme.
- One consistent outer box. Keep the mailer the same and change the inside card or a sleeve each month; it keeps packaging costs fixed while content changes.
- Design for the camera. High-contrast inside print and a tidy layout look good in vertical video.
- Plan for churn and pauses. Order in quantities that match your subscriber count plus a buffer, and reorder on a schedule.
Frequently asked questions
What is the best material for a subscription box?
E-flute corrugated is the standard: it prints well, folds into a crisp mailer and protects most products in the mail. Heavier or fragile items move to B-flute or a stronger board.
How does dimensional weight affect my shipping costs?
Carriers bill the greater of actual and dimensional weight. UPS and FedEx divide L × W × H by 139 for packages of any size, and since July 12, 2026 USPS does the same for parcels over one cubic foot, with dimensions rounded up to the next inch. Tightly sized boxes now save more than before.
Can you print inside the mailer?
Yes. Inside printing — from a one-color message to full-color patterns — is the most popular subscription upgrade.
Can my mailer be reused for returns?
Yes. A tear strip plus a second adhesive strip lets customers reseal the box for returns.
Can you drop-test my box design?
Designs can be tested to ISTA 3A or Amazon ISTA-6 profiles on request. Ask for testing when you request a quote, as it adds time and cost.
Cut shipping cost and raise the unboxing bar.
Send your product mix and current box size. We’ll suggest mailer sizes and a spec.