Overview & Specifications
What Are Custom Clothing Boxes?
Custom clothing boxes are shipping and presentation mailers sized around folded garments, accessories and coordinated clothing sets. Packaging Dock builds them as one-piece Roll End Tuck Top mailers that ship flat and fold up at packing, with exterior and interior print connecting the fulfillment package to the apparel brand.
They are part of the Mailer Boxes range and Packaging Dock's Apparel & Fashion Packaging.
What it has to do
What a Clothing Order Needs from a Shipping Box
A clothing box has to fit the folded garment, avoid paying to ship empty space, leave room for tissue and cards, hold accessories and present the brand.
01
Fit
Fit the Folded Garment
Box dimensions should follow the garment's actual folded width, length and stack height. Tissue, protective layers, cards and accessories should be included when establishing the final packed dimensions.02
Avoid
Avoid Shipping Empty Space
A product-focused mailer can reduce excess interior space while leaving appropriate room for packing materials. The closed outside dimensions can affect shipping charges under the carrier service and account terms. Compare the proposed package against the applicable rate calculation.03
Leave
Leave Room for Tissue and Cards
Tissue, cards and a printed inside lid build the reveal; their thickness is added to the stack height when sizing.04
Hold
Hold Accessories in Sets
Inserts or dividers can be added when multiple garments or accessories require separate positions.05
Present
Present the Brand
Exterior and interior printing can connect the fulfillment package with the apparel brand, creating a consistent handoff from warehouse to customer.
The Mailer Construction Used Here
Custom clothing boxes are Roll End Tuck Top Boxes: a shallow folding mailer with rolled walls and an attached tuck-top lid. Develop the inside depth around the finished fold and presentation layers so the lid meets the packed garment stack cleanly.
For a two-piece reveal of folded garments, see the separate Roll End Boxes with Lid; Roll End Tuck Front and Roll End 3 Flap Lock are the other mailer products.
Clothing Box vs Poly Mailer
A clothing box uses folded board walls to define the garment layout and opening experience. A poly mailer conforms around the packed contents. Compare the complete packed order, presentation requirements and delivery route before choosing between them.
| Attribute | Custom Clothing Box | Poly Mailer |
|---|---|---|
| Material | Paperboard or corrugated | Flexible plastic film |
| Shape | Defined board walls around the packed fold | Conforms to the contents |
| Opening presentation | Inside-lid artwork and tissue where specified | Flexible opening; print and contents depend on the chosen product |
| Typical use | Branded DTC orders, drops, PR kits | Low-cost soft-goods shipping |
Custom Clothing Box Specifications
Custom clothing boxes are specified around garment fold, packed set, board and interior presentation. Review the specifications below to plan the mailer, interior and production.
| Specification | Available Configuration |
|---|---|
| Product Type | Apparel-focused Roll End Tuck Top mailer |
| Category | Mailer Boxes |
| Construction | Roll End Tuck Top mailer: one-piece die-cut blank, rolled double-layer walls, attached tuck-top lid |
| Dimensions | Customized around garment fold and packed set |
| Board | Paperboard or E-/B-flute corrugated, selected according to product weight, supports and distribution route; paperboard builds may require an outer shipper |
| Interior | Tissue, cards, dividers or inserts where required |
| Inserts | Paperboard, corrugated, foam/EVA or molded pulp; thermoformed PET/PVC trays also offered for mailers |
| Ecommerce Features | Tear strip, adhesive strip, tongue lock, pocket or card slot, where specified |
| Print Coverage | Exterior only, exterior plus inside lid, or broader inside/outside coverage where the board and print method support it |
| Print Methods | Offset, digital, UV, screen or flexographic printing; CMYK and Pantone spot colors |
| Finishes | Matte, gloss or soft-touch lamination, aqueous coating, foil stamping, emboss/deboss, Spot UV and raised 3D UV, according to the board |
| Starting Price | From $1.45 / unit; final price depends on size, board, print coverage, inserts, finishes and quantity |
| Minimum Order | 500 units |
| Standard Production | 7 days from approved proof |
| Rush Production | Available on request |
| Shipping | Ships flat, USA and worldwide |
What Size Clothing Box Do I Need?
Size the box from the folded garment: measure folded width and length, then the stack height with tissue, cards and accessories. Shallow depths suit single tees and knits; deeper boxes suit sets, knitwear or folded outerwear.
| Measurement | Include |
|---|---|
| Product or inner pack | Full dimensions, closures and intended orientation |
| Interior arrangement | Inserts, partitions, cushioning and presentation layers |
| Complete shipment | Packed weight and units per box |
| Final box | Inside fit and closed outside dimensions |
Confirm the finished fit on the approved dieline and a loaded sample where required. General allowances and common starting sizes are on the Roll End Tuck Top sizing guide.
Test the Fold Used by the Packing Team
Use the fold, garment sizes and presentation layers that will be used in production. Check the packed stack with the lid closed, including accessory compartments, then repeat with the smallest and largest intended orders.
What to Check Before Bulk Production
Trial the clothing box with folded garments, tissue and cards. Record the approved fold depth, board and tissue layout on the sample.
| If the trial shows | Review before approval |
|---|---|
| Garment stack presses the lid | Review the production fold and presentation-layer thickness |
| Small orders leave excess space | Compare a smaller size or adjusted interior layout |
| Accessories shift into the garment | Review compartment positioning |
The stated seven days covers standard production from approved proof once the specification is confirmed. Confirm dispatch and delivery timing for the destination separately.
