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Mailer Boxes With Sleeves
Custom mailer boxes with sleeves combine protective shipping design with a premium unboxing layer.A Customized Packaging Experience For your Branding Needs
Product OverviewTwo-part construction featuring a base mailer box and a detachable sleeve | Board StrengthMailer: 400–600 gsm and Sleeve: 250–350 gsm paperboard | Structure & BuildSleeves can be printed, foiled, or die-cut; they can include inserts |
Material OptionsSleeves and boxes can be made from Kraft, white coated board, or SBS paperboard, | KraftEco-friendly and tactile — ideal for sustainable brands. | White Coated BoardSmooth, bright surface for luxury finishes and vivid colors |
Printing MethodSupports CMYK and Pantone processes for brand-accurate color reproduction | Dual Surface PrintContrasting inside/outside color schemes for layered visual impact. | UV or Spot FinishesUsed selectively to highlight brand marks or create texture variation |
Understanding the Construction of Mailer Boxes with Sleeves
Designing sleeve-style mailers requires precise fit engineering — too tight, and the sleeve scuffs; too loose, and it loses elegance. Both parts must align structurally and visually, ensuring seamless motion, strength, and shelf presence.
Fit & ToleranceSlide That Feels EffortlessLayered lids, pull-out trays, or hinged openings create cinematic unboxing moments. Reinforced creases and double-wall construction prevent bowing during repeated openings.
Construction TechniquesMaterial Matching:Two Layers, One StoryUse compatible GSM ranges between box and sleeve to prevent compression or warping. Heavier coatings may need a slightly looser fit.
Design & BrandingPrint Smart, Align PerfectlyEnsure artwork continuity across sleeve and base. The design must align seamlessly when assembled for a polished, retail-grade finish.
Making Your Brand Unforgettable
Need Help Designing Your Mailer Boxes?
We provide free in-house design support
Frequently Asked Questions
Get answers to common questions about custom rigid boxes, or visit our Help Centre for further information.Are sleeves and boxes printed separately?
It Depends on your artwork. However, Both components can be printed and finished independently, allowing creative combinations of color, texture, or messaging.
Are these boxes suitable for shipping?
Absolutely. The inner mailer is built from durable corrugated board, ensuring full transit protection.
Are sleeve mailers cost-effective?
They use standard mailer structures with only the sleeve customized, reducing tooling and production costs. We can fully accomodate your cost & budget constraints.
Can these be produced in low MOQs?
Digital printing enables short-run customization for influencer kits or limited editions without high setup costs. Get in touch with our team for more detailed understanding and cost optimization in low moqs.
