- +1 305 574 4357
- sales@boxbaba.com
- 7901 4th St N, St. Petersburg, FLORIDA, US, 33702
Apparel Mailer Boxes by BoxBaba USA provide durable, eco-friendly custom packaging designed for clothing shipping. Personalize sizes, colors, finishes, and logo printing to boost brand appeal and customer experience. Order Custom Mailers Today!
Create Custom Boxes Quick and Easy
Get your custom boxes made in the required size, shape, and style.
Upload your artwork and get it superbly printed the way you want.
Order any quantity, enjoy a wholesale price, pay no extra for die plates.
| Specification | Details |
|---|---|
| Box Style | Fully customizable apparel mailer boxes, folding carton, magnetic closure, drawer, shoulder neck, mailer, or specialty box styles |
| Dimensions (L × W × H) | Custom sizes manufactured according to your exact product dimensions and structural requirements |
| Order Quantity (MOQ) | 100 units minimum (flexible for specific projects) |
| Material Options | 10pt–24pt SBS Kraft board, corrugated (B, E flute), high-density greyboard for rigid boxes |
| Printing Options | CMYK offset printing, Pantone (PMS) color matching, inside & outside printing |
| Print Finishes | Matte lamination, Gloss lamination, Soft-touch coating, Aqueous coating, UV coating |
| Premium Enhancements | Foil stamping (gold/silver/custom colors), Embossing, Debossing, Spot UV, Raised UV |
| Insert Options | EVA foam inserts, Die-cut paperboard inserts, Molded pulp, Cardboard dividers, Custom fit structural inserts |
| Embellishments | Ribbons, magnetic closures, bows, glitters, sparkles, custom tags & hang tags |
| Compliance Support | Labeling guidance & compliance support available for regulated products including hemp/CBD packaging |
| Sampling & Proofing | Free 3D digital mockups, blank sample, printed sample (delivery reimbursable) |
| Production Timeline | 5–9 business days standard production (rush orders available upon discussion) |
| Shipping | Free USA shipping; flat-packed or assembled shipping options available |
Packaging materials do more than hold a product; they influence protection, presentation and overall box performance. Cardboard provides a smooth, durable surface for custom printing and everyday retail packaging. Kraft paper offers a natural, sturdy option with an eco-conscious appearance. Corrugated stock adds extra strength for heavier products and shipping applications. We offer carefully selected paper stocks that balance durability, print quality, sustainability, affordability and premium presentation.
Printing methods enhance how your packaging looks and represents your brand. Digital printing delivers sharp details and vibrant colors, making it ideal for flexible custom packaging designs. Offset printing provides consistent color accuracy and crisp image quality for larger production runs. Screen printing creates bold, durable graphics on selected box surfaces and materials. We offer the latest printing methods to turn your creative ideas into realistic visuals, showcasing logos, patterns, artwork and branded graphics with clarity and precision.
Printing inks bring packaging artwork to life with vibrant colors, clear details and consistent brand presentation. We offer a wide range of ink options, including Pantone colors, Pantone Metallic inks, oil-based inks and fluorescent inks for distinctive visual effects. Soy and vegetable-based inks provide versatile color reproduction, while water-based inks offer another practical printing option. Choose the right ink to reproduce logos, patterns, illustrations and branded artwork, turning creative ideas into attractive visuals with striking color and clarity.
Premium finishes enhance the appearance and overall aesthetics of custom packaging. Matte and gloss laminations create smooth visual effects, while soft-touch adds a refined tactile feel. Foil stamping introduces metallic accents in gold, silver and other shades, while embossing and debossing add dimensional detail. Spot UV highlights selected design elements with added contrast and shine. Choose from versatile finishing options to make logos, patterns and branded artwork look more distinctive, polished and premium.
Packaging add-ons make custom packaging more attractive, presentable and visually captivating while increasing its perceived value. Gold foil adds a rich metallic accent, while silver foil creates a clean and sophisticated look. Holographic foil introduces eye-catching reflective effects that help selected design elements stand out. Embossing raises logos or patterns for added dimension, while debossing creates a refined recessed effect. Ribbons and handles add both decorative appeal and practical convenience, giving packaging a more distinctive and premium presentation.
| Specification | Details |
|---|---|
| Box Style | Fully customizable apparel mailer boxes, folding carton, magnetic closure, drawer, shoulder neck, mailer, or specialty box styles |
| Dimensions (L × W × H) | Custom sizes manufactured according to your exact product dimensions and structural requirements |
| Order Quantity (MOQ) | 100 units minimum (flexible for specific projects) |
| Material Options | 10pt–24pt SBS Kraft board, corrugated (B, E flute), high-density greyboard for rigid boxes |
| Printing Options | CMYK offset printing, Pantone (PMS) color matching, inside & outside printing |
| Print Finishes | Matte lamination, Gloss lamination, Soft-touch coating, Aqueous coating, UV coating |
| Premium Enhancements | Foil stamping (gold/silver/custom colors), Embossing, Debossing, Spot UV, Raised UV |
| Insert Options | EVA foam inserts, Die-cut paperboard inserts, Molded pulp, Cardboard dividers, Custom fit structural inserts |
| Embellishments | Ribbons, magnetic closures, bows, glitters, sparkles, custom tags & hang tags |
| Compliance Support | Labeling guidance & compliance support available for regulated products including hemp/CBD packaging |
| Sampling & Proofing | Free 3D digital mockups, blank sample, printed sample (delivery reimbursable) |
| Production Timeline | 5–9 business days standard production (rush orders available upon discussion) |
| Shipping | Free USA shipping; flat-packed or assembled shipping options available |
We use cardboard material with the least environmental impact and minimizes waste generation.
Kraft paper is a strong, durable and reliable material that is widely used across many different industries.
Rigid is highly protective, affordable and recyclable material. These boxes provide maximum protection.
Corrugated material is easy to customize, cost effective and sustainable. It is also great for branding purposes.
Enhance your packaging with premium foil stamping for a bold and luxurious appearance.
Our Spot UV coating adds a sleek shine and highlights key design elements beautifully.
Give your packaging a polished, glossy finish that enhances color and visual appeal.
Create eye-catching packaging with holographic foil effects that shimmer from every angle.
Add raised textures and elegant detailing to make your packaging stand out.
Create a refined pressed-in effect that adds depth and sophistication to your packaging.
Achieve a smooth matte finish that minimizes fingerprints and delivers a modern look.
Protect your packaging with a silky-soft laminated finish for a premium feel.
Ensure your apparel brand stands out right up to the doorstep with BoxBaba’s apparel mailer boxes. Designed for U.S. retailers, eCommerce brands and DTC apparel lines, our branded shipping-boxes combine protective structure, premium printing and sustainable materials — built to boost brand perception, reduce return damage and maximize unboxing appeal.
In apparel packaging, shipping boxes are more than transit—they’re part of the brand experience. At BoxBaba we specialise in apparel mailer boxes manufactured in the USA that deliver:
Transit-grade protection for garments—reducing returns caused by damage or mishandling.
Brand-first design and printing — full-colour, CMYK + PMS, inside/out printing, logos, campaign messages.
Flexible production and wholesale capability—suitable for boutique brands to high-volume orders.
Sustainable options: recycled corrugated materials, lower-waste designs, and eco finishes aligning with apparel packaging trends.
Optimised sizing and structure to minimise shipping cost, dimensional weight and void-fill while improving garment presentation.
When it comes to apparel mailer boxes, structure and material matter. BoxBaba offers:
Materials: high-quality corrugated cardboard (32 ECT standard, up to 44 ECT for heavier items) for durability in transit.
Box structure: self-locking flaps, tuck-in/mail-style closing, flat-pack shipping-friendly design, easy to assemble.
Print & finish: full-colour branding, spot UV, foil stamping, embossing, soft-touch coating—elevating a shipping box into a branded experience.
Fit-for-purpose size: custom dimensions to suit t-shirts, hoodies, jeans or multi-item orders—reducing movement and damage.
Every apparel brand has a distinctive voice and packaging should reflect that. At BoxBaba you can customise:
Box sizes and formats to align with your garment types: tees vs outerwear vs bundles.
Full-colour and PMS colour-matched printing for your brand identity, campaigns and seasonal themes.
Finishing touches: custom inserts/trays to hold folded garments, branded tissue wrap, thank-you cards, return instructions printed inside.
Eco-friendly variant: recycled or FSC-certified materials, minimal glues/coatings, plastic-free finishes aligning with sustainability trends in apparel packaging.
The logistics of shipping apparel demand packaging that works both in transit and for brand experience:
Designed for eCommerce workflows: flat shipping, self-locking closures, easy packing and returns.
Suitable for retail or DTC apparel brands that want packaging to match product quality and brand identity.
Reduces return rate by protecting garments from creasing, crushing and damage during shipping.
Right-sizing boxes to minimise shipping costs and dimensional weight while still delivering premium unboxing.
Modern apparel consumers expect packaging that aligns with brand values and environmental standards. BoxBaba ensures:
Use of recycled corrugated board, FSC-certified material, water-based or soy-based inks, minimal varnish/coating for recyclability.
Quality control on print registration, structural strength, accurate sizing, color fidelity and closure integrity.
Packaging engineered for strong unboxing experience: protective fit, branded impression, supports returnable or reuse options.
Ready to elevate your apparel brand’s shipping and unboxing experience? Contact BoxBaba now for a tailored consultation. We’ll walk you through sizes, styles, materials, finishes and bulk pricing. Get your free quote today and deliver apparel mailer boxes that protect your garments, amplify your brand and convert customers.
Transform your apparel brand’s shipping into a premium experience with BoxBaba’s custom apparel mailer boxes. From protective structure to branded presentation and eco-conscious materials—this is packaging built for eCommerce, retail and DTC apparel brands. Request your free quote today and elevate every garment’s journey.
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