Envelope Mailer
Give your products the perfect blend of protection and presentation with custom envelope mailers designed to keep flat, delicate items safe in transit while showcasing your brand beautifully. These slim, rigid, self-sealing mailers are crafted to prevent bending and deliver a premium unboxing experience. Whether you need bold graphics, minimal branding, or eco-friendly construction, our custom mailers ensure your shipments look professional from the moment they arrive. Protect your items, impress your customers, and strengthen your brand identity, all with a single envelope mailer. Get a Quote and start your order today.
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“Elixir Packaging was wonderful to work with! I needed custom boxes for my ecommerce business quickly. They were able to make the boxes quickly,…”
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How it works
From quote to delivery in four simple steps.
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Get a quote
Send your size, material and quantity — we'll price it for you.
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Free design & dieline
Our designers prepare your dieline and a realistic 3D mockup — at no cost.
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Approve digital proof
Review and sign off on the exact colours and layout before anything prints.
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Production & delivery
We print, finish and ship your order to your door with care.
What Are Envelope Mailers?
Envelope mailers are flat, rigid envelope mailers made from sturdy 24–28 pt paperboard that protect items that must stay flat during shipping. These paperboard mailers prevent bending, creasing, and pressure damage, making them ideal for documents, photos, artwork, catalogs, stickers, and other thin products. Designed with a strong self-seal closure, they offer secure packaging while keeping your shipments lightweight and cost-efficient.
Why Choose Custom Envelope Mailers?
Custom envelope mailers offer superior bending resistance due to their rigid paperboard structure, making them perfect for delicate, flat items. Fully branded printing allows your branded mailer envelope to create a memorable impression with every delivery. They’re lighter than boxes, helping reduce shipping costs while still offering premium protection. Many options are recyclable, supporting sustainability goals with eco-friendly envelope mailer choices.
Durable Material Options for Branded Mailers Envelope
Our padded mailers are crafted from high-caliper paperboard mailers (24–28 pt) that deliver strong durability and bending resistance. Each rigid “do-not-bend” mailer includes a reliable self-seal envelope mailer adhesive strip to ensure fast packing and tamper-resistant closure. The structure stays firm during transit, making it ideal for USPS, UPS, and FedEx shipping. Most paperboard options are curbside recyclable, offering an eco-friendly solution for brands.
Customization & Printing Options for the Envelope Mailer
Create custom paperboard mailers that perfectly match your branding. Choose full-color CMYK or PMS printing for vivid artwork inside and out. Add matte, gloss, or soft-touch coatings to enhance the tactile feel and elevate your brand image. Whether you want patterns on poly mailers, minimalist logo placement, or promotional themes, our design team assists with artwork, mock-ups, and final proofing, making it easy to design a printed envelope mailer for business.
Industries that Use Custom Envelope Mailers
These mailers work perfectly for:
- Marketing collateral: catalogs, brochures, flyers
- Press kits and event mailers
- Stickers, decals, and flat merchandise
- Unbendable shipments like photos, art prints, and documents
- Subscription inserts and branded promotional mailer envelope campaigns
Their rigid structure ensures products arrive exactly as intended.
How to Order Custom Envelope Mailers?
It’s simple, fast, and perfect for brands looking to order custom envelope mailers with ease.
- Request a quote and share your required size, quantity, and design preferences.
- Submit your artwork or take advantage of our free professional design support.
- Review and approve your digital or physical proof before production.
- Production begins with strict quality checks at every stage.
- Mailers are shipped directly to your address, ready for use.
Wholesale Prices of Customized Envelope Mailers with Low MOQs
We offer flexible MOQs to support both small and large businesses. Pricing varies based on size, board thickness, printing coverage, and order quantity, with cost savings available for bulk orders. Standard production time includes proofing, manufacturing, and prompt delivery, ensuring a smooth, reliable process.
Why Choose Elixir Packaging for Custom Envelope Mailers?
Elixir Packaging gives your products the protection and presentation they deserve. Our rigid paperboard mailers offer superior durability, preventing bending, pressure damage, and mishandling during shipping, while the secure self-seal strip keeps every package tamper-evident and intact. We also provide sustainable options such as recycled paperboard, FSC-certified materials, and water-based inks, all fully curbside recyclable in most U.S. regions, to support eco-friendly brand values. With premium customization and standout branding, your mailers not only keep items safe but also elevate your overall customer experience. Start designing your custom envelope mailers today and request a free quote with Elixir Packaging
| Dimensions | Available in all Custom Sizes |
|---|---|
| Quantities | Starts from 0 to Unlimited |
| Printing | CMYK, PMS, Without printing, Off-set printing, Digital printing |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Options | Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink, Lamination, Spot UV, Foil stamping, Embossing, Debossing |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Card stock |
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
| Turn-Around Time | Regular (5 to 7 Business Days to ship), Rush order( On Request ) |
Digital Printing
Flexographic Printing
Screen Printing
Gloss Coating
Matte Coating
Soft Touch Coating
Spot UV Coating
Foil Stamping
Embossing
Debossing
Die Cutting
SBS (Solid Bleached Sulfate)
CCNB
Kraft Paperboard
C1S/C2S
Single Wall Corrugated
Double Wall Corrugated
Triple Wall Corrugated
B-Flute
C-Flute
E-Flute
F-Flute
5.0
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Michael S. CecilRated 5 out of 5
Obsessed with the durability of Elixir Packaging's envelope mailers. No more worries about my products getting bent or damaged in transit - they're a lifesaver for my small business!
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Frequently asked questions
Everything you need to know before you order.
What thickness of board do you use for custom envelope mailers?
Our rigid envelope mailers use strong 24–28 pt paperboard to ensure maximum shipping protection.
Can I print on both sides of my custom envelope mailers?
Yes, you can enjoy full external and internal printing for premium, brand-focused custom mailer packaging.
Are custom paperboard mailers recyclable?
Most custom paperboard mailers are curbside recyclable, depending on your selected material.
Do you support custom sizes for rigid envelope mailers?
Yes, we offer full customization for any custom rigid envelope mailer size you need
What is the minimum order quantity for custom envelope mailers?
We offer low MOQs, making our custom mailer packaging accessible for all business sizes.
