Custom box mailers are a versatile packaging option for shipping products, gifting, and creating premium unboxing experiences. We offer several styles, materials, and print methods to fit your project needs, from quick-turn domestic options to fully custom boxes with special finishes, which are produced overseas.
What type of boxes do you offer?
1. Corrugated Mailers
Best For: Subscription boxes, influencer kits, e-commerce shipments
Material: Sturdy corrugated cardboard, available in kraft or white base
Print Methods: Digital (best for small runs), Offset (best quality for 500+ units)
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Customization Options:
Inside/outside printing
Tray inserts to hold items in place
Matte, gloss, or soft-touch finishes
2. Rigid Boxes
Best For: Beauty products, luxury items, VIP gifts, high-value launches
Material: Thick chipboard wrapped in printed paper
Closure Styles: Magnetic flap, lift-off lid, two-piece telescope, or drawer-style
Customization Options: Foil stamping, embossing, debossing, spot UV, specialty laminations
What are production lead times?
| Product Type | MOQ | Lead Time | Notes |
|---|---|---|---|
| Corrugated Mailers | 100 units | 2–3 weeks from proof approval | Fast turnaround, great for smaller runs |
| Corrugated Mailers with Tray Inserts | 100 units | 4-6 weeks total | Great option for quick turnaround projects that are more customized |
| Rigid Boxes | 300–500 units | 3–4 months total | Highest quality, widest customization options, longer lead times |
How Does the Process Work?
Domestic Production (3-4 weeks)
Share box dimensions, quantity, and design mock-ups
You send product samples if we're building a custom tray insert
We provide you with box dielines for design
You submit your artwork on dielines provided
Production takes 2–3 weeks from proof approval
Overseas Production (3-4 months)
Share box dimensions, quantity, and design mock-ups
You ship product samples to manufacturer overseas
Blank samples are produced in 1 week
Dielines are provided in 1 week
You submit final artwork on dielines provided
Printed sample is produced in 2 weeks
Full production takes 4-5 weeks from printed sample approval
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Allow 2-3 weeks for air express shipping or 4-5 weeks for ocean freight shipping
Can Gemnote produce box designs?
Yes! Gemnote can help with designs for an hourly fee and 2-hour project minimum. Note that Gemnote does not come up with box concepts and structural designs, but can help produce artwork if you provide us with brand guidelines, assets and inspiration of what you're looking to produce. If your team is able to produce designs, please note:
Ready-to-print artwork should be included on box dielines
Include bleeds and keep key elements inside safe zones
Vector artwork must be provided - avoid flattening the designs
Ready to start a custom box project?
Please complete the Start a Project form and include that you are interested in custom boxes or branded packaging. Our team will review your project details and follow up with available options, estimated timelines, MOQs, and pricing when available.