The biggest mistake founders make on mailer box is optimizing for Instagram unboxing photos but forgetting the warehouse. A mailer that looks great on day 1 has to also stack 12-high in a fulfillment warehouse, survive a UPS sort line, and arrive at the customer's door without crushed corners or popped seams.

We engineer every mailer box run for both. The print runs on HP Indigo 15K — the largest digital sheet press in the Indigo family, so we fit more boxes per sheet. The die-cut runs on a Heidelberg cylinder or a Bobst flatbed for tight tolerances on the fold lines. The glue runs on a Bobst Mistral. All in our LA building, in one cell.

One quoted number — no buried setup fee

Most mailer box printers quote a low per-piece price, then bury a heavy tooling fee in the proposal. Bazaar quotes one number. Start a Quote for live pricing — the configurator shows volume breaks as you adjust qty. Launching brands can run a sample batch with the full finish stack (Scodix raised UV, JetFX gold foil, soft-touch lamination), take them into 5 buyer meetings, and then come back to print thousands with the same artwork.

We build the die once, store it, and reuse it on every reorder. Your unit pricing drops noticeably on the second run with no "new" setup. Same artwork file, same dieline, same press — just a faster, cheaper rerun.

What goes into a great mailer box order

The choices that matter: box style (mailer, tuck-end, tray-and-lid, sleeve), exterior finish (soft-touch lamination feels premium; matte feels modern; gloss feels punchy), interior print (yes — you can print the inside of the lid for a brand moment), and insert configuration (corrugated dividers, foam, custom-die cradles for fragile product).

On every mailer box order, our designer reviews the dieline against the product dimensions you send us. If the fit is going to be sloppy or the print clips into the seam, we'll flag it before press. For brands launching their first run, this review alone saves the most painful kind of mistake — opening 500 boxes and finding the product doesn't fit.

In-house

HP Indigo 15K + 6K, Karlville, Scodix

306 Boyd St · walk in or ship

5+ days

Standard turnaround · rush available

Designer on staff

Free file review before you pay

Common questions

What sizes do you offer for mailer box?

Any size — we build custom dies from your product dimensions. For mailer boxes, the standard range is 4x4x2 up to 18x12x6. Bubble mailers come in #000 through #7 stock sizes, custom-printed. Send the product dimensions and we'll quote the right outer.

Can I get printed interior on mailer box?

Yes — interior print is the founder favorite. We print the inside of the lid (where most brands put a thank-you note or a tagline) at the same per-piece price as exterior print. No surcharge, no second-pass cost.

How heavy is the corrugated stock you use for mailer box?

Default is 32 ECT B-flute for ecommerce mailers — the right balance of crush resistance and print quality. Heavier 44 ECT C-flute is available for larger boxes or fragile product. We'll recommend based on your contents.

Can you add a custom insert or divider to mailer box?

Yes — we die-cut corrugated inserts, foam, and chipboard cradles in-house. Send us product dimensions and we'll mock up a dieline at scale, free, before you commit.

Where is Bazaar Printing located?

306 Boyd Street in downtown Los Angeles. Walk-in pickup is free during business hours. We also ship national via UPS and FedEx, and rush-courier within Southern California.

How fast can you turn around an order?

Standard turnaround is 5 business days for labels and stickers, 7–10 days for pouches and cartons, 5–7 days for hang tags and inserts. Rush (3 days) is +40%. Express (next-day) is +80% on label and sticker orders where capacity allows.

Print mailer box that ship.

Get an instant quote on a 3D box editor, or talk to a real packaging engineer first. Most orders ship in 7–10 business days.

Start a quote Talk to us