Custom End Opening Mailer Boxes Printed to Your Size

What is an end opening mailer box?

An end opening mailer is a folding corrugated box with a hinge along the back. You open it by lifting the lid at the short front end.

The side panels roll over and lock into the base. That keeps the corners square without glue or staples. A front flap tucks under the lid to hold everything shut.

If you want a slim carton that slides open instead, look at our side loading mailers for slim items.

Why choose an end opening lid over a side opening one?

A lid that opens from the short end swings up like a book cover. The inside of that lid faces your customer, so it is a natural spot for a note or setup steps.

The back hinge also keeps the box closed while it stands on a shelf. The rolled ends add stiffness where people grip the box, which helps when it gets carried around a warehouse or an office.

How do I choose the right inside size?

Lay out every item the way it will be packed. Include tissue, cards and any divider.

Measure that arrangement and send us the inside length, width and height in inches. Our guide to measuring a box shows exactly where to place the tape.

This style works best low and wide. A tall box makes the lid heavy and floppy when it opens.

Try a mock-up from scrap cardboard at your chosen size. If the lid closes flat and nothing slides when you shake it gently, the size works. If the lid bulges, add height.

Which board should I pick for an end opening mailer?

Most of these boxes are single wall. The rolled ends already add strength, so the flute choice comes down to what you are packing and how you print.

White board gives brighter color. Kraft gives a warmer, earthier look, and one color ink often looks best on it. For photos or bright brand shades, white E flute is the safer pick. The corrugated board flute guide explains the differences in more detail.

Can I add dividers or an insert?

Yes. One card divider down the middle keeps two products apart so they stop knocking together. A cut insert can hold bottles, tins or small gadgets in fixed spots.

Share each item's dimensions and the way you plan to lay them out. We quote the box and the layout together, so the fit is planned from day one. See our cut corrugated inserts for fixed items for more ideas.

How should I print the lid and the ends?

The underside of the lid is the best space on the box. Put a thank-you line, a short how-to or a QR code there.

We print plain, one color, two color or full color CMYK, inside and outside. For finishes, you can pick embossing, foil stamping, spot UV, or matte or gloss lamination. You can also leave kraft uncoated.

Think about the order people see things. The end panel shows on a shelf, the top shows on a porch, and the lid shows last. Give each panel its own job. Place your logo with Design Your Box and our designers will check the layout for free.

What mistakes should I avoid?

Height is the usual problem. Tall products are easier to pack in a tuck top mailer for taller items.

Artwork that runs across a rolled fold can look broken once the box is built. Check the proof, because it marks every fold and cut.

Many buyers also forget to count the divider. Even thin card takes up space, and three dividers take more. Finally, a very thin board saves little and can leave the lid bent after a few trips. Ask us before you approve the quote if you are unsure.