Double Wall Mailer Boxes UK

About our box

Double Wall Mailer Boxes, made to your size

When a standard mailer is not enough, double wall board gives you the extra strength. It combines two layers of flute for greater crush resistance and stacking strength, making it ideal for heavier products, glass and anything that travels through busy courier networks.

Why choose our double Wall Mailer Boxes

Damaged deliveries cost more than the box. Double wall mailers reduce breakages and returns for heavy or fragile items while still giving you a clean, printable surface for your branding.

Popular uses

Glass bottles and jars
Heavier homeware and ceramics
Multi-item bundles
Tools and hardware
Wholesale and trade orders

Materials, print and finishes

Double wall (BC-flute or EB-flute) board
High crush and stacking strength
Kraft or white outer liner for print
Pairs with inserts for fragile items

For very fragile products, combine double wall board with a fitted insert. We will recommend the right combination in your quote.

Sizes and dimensions

Every order of double Wall Mailer Boxes is made to your dimensions in millimetres (length × width × height). Not sure of the size? Choose “Not sure — suggest a size” in the options above and tell us what you are packing, and we will recommend dimensions and show them in your mock-up. You can also order several sizes in the same design to cover your whole range.

Related packaging

Comparing options? Take a look at Corrugated Mailer Boxes, Shipping Boxes and Mailer Boxes With Inserts, or browse all custom mailer boxes and our wider custom packaging range.

How to order

Choose your size and options above and request a free quote. We reply within 24 hours with your price and a free 3D mock-up, and nothing is printed until you approve it. Orders are delivered across the UK in 12–14 working days; see our delivery information. The “From” price is our bulk price per unit, excluding VAT, and larger quantities bring the unit price down. Selling clothing too? We also make custom apparel to ship in your boxes.

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Specifications

Board	Double wall corrugated (≈4–7 mm)
Style	Self-locking mailer, tape-free
Print	CMYK and Pantone, outside, inside or both
Finishes	Matte, gloss or soft-touch; foil, spot UV, embossing
Size	Made to your inside dimensions (mm)
Recyclable	Yes, with UK paper and card recycling
Minimum order	Low minimums
Delivery	12–14 working days after approval, UK-wide
Category	Custom Mailer Boxes

New · Custom Apparel

Fill your boxes with your own merch

Hoodies, tees, sets, caps and socks — cut and sewn to your design from 20 pieces per style, packed in your boxes and delivered together.

Explore custom apparel

How it works

Tell us your box
Size, print and quantity — or ask us to suggest a size.
Free 3D mock-up
See your design on the box before anything prints.
We print and make
Printed, die-cut and quality checked.
Delivered flat
Tracked UK delivery in 12–14 working days.

Questions about Double Wall Mailer Boxes

How much weight can a double wall mailer hold?

It depends on the size, but double wall mailers comfortably handle heavier loads than single wall. Tell us your product weight and we will confirm the right board.

Can double wall boxes be printed in full colour?

Yes. We print directly on a white or kraft outer liner, or use a printed litho-laminated sheet for the highest print quality.

How much do double wall mailer boxes cost?

The “From” price on this page is our bulk price per unit, excluding VAT. Your exact price depends on size, quantity, print and finish, and we send it with a free mock-up within 24 hours.

How long does delivery take?

12–14 working days after you approve your mock-up, with tracked delivery anywhere in the UK.