Custom Printed Mailers
Feel the quality before you commit.
Free.
Get a TerraBoard sample kit on your desk and elevate how you think about your customer's unpacking experience. Hold the 100% recycled material, test the closures, compare the sizes — then order with total confidence.
17M+
shipments
100%
plastic-free
No
minimum order
Request a Sample Kit
60+ years
US manufacturing
100%
plastic-free
Low MOQ
Start small, scale up
Custom Printed Mailers
Put your brand on packaging customers
Remember.
Custom-printed, 100% recycled mailers made entirely in the USA. We're the manufacturer — so you get true factory pricing, low minimums, and turnaround no reseller can match. Your logo, your sizes, your unboxing moment.
60+ years
US manufacturing
100%
plastic-free
Low MOQ
Start small, scale up
17M+
shipments
100%
plastic-free
No
minimum order
100%
Recyclable
FSC
Certified Paper
Low MOQ
Low Minimums
Custom
Printing
American
Made
Our Products
Everything you need to see and feel the difference
One free kit, the full picture — real material, real sizes, real closures.
most Popular
Flat Mailers
For apparel, textiles & soft goods
6x9"
9×12"
10×13"
12×15"
+5 more
most Popular
Expandable Mailers
For bulkier & multi-item orders
7×10"
9×12"
10×13"
12×15"
Custom
Printed Sample
See how custom branding looks
Two Color
Single Color
Kraft
White
A selection of real sizes, closures & construction
100% recycled, recyclable & biodegradable
No cost,
no obligation
Want some more information before you order
Why Branded Sustainable Mailers Matter
Packaging is marketing,
identity & loyalty
Real custom print on 100% recycled material — the unboxing your customers photograph and share.
Builds brand recognition
Every shipment reinforces your identity. A branded mailer turns logistics into a touchpoint customers remember.
Signals sustainability
100% recycled, plastic-free packaging strengthens trust with the eco-conscious buyers driving e-commerce growth.
Drives repeat purchases
A memorable unboxing moment increases loyalty and referrals — turning one order into a returning customer.
most Popular
Flat Mailers
Rigid and tear-resistant. Perfect for apparel, documents, prints, and thin items. Clean exterior for labels or custom branding.
6x9"
9×12"
10×13"
12×15"
+5 more
most Popular
Expandable Mailers
Designed to protect soft goods, lifestyle products, and small-batch eCommerce shipments with sustainable cushioning.
7×10"
9×12"
10×13"
12×15"
Custom
Custom Branded
Your brand on every mailer.
Two Color
Single Color
Kraft
White
Simple Process
From your logo to your loading dock
We support a sustainable loop every step of the way. Brands switching to TerraBoard report measurable reductions in both carbon footprint and carrier fees.
1
Request a quote
Tell us roughly what you need. A specialist follows up — no full spec required to start.
2
We size & proof
We help you pick the right sizes and send a print proof of your branded design for approval.
3
We print in-house
Curbside recyclable & plastic-free
4
Ship & reorder
Fast delivery, manufacturer-direct pricing, and easy reorders as you grow.
Custom Orders
Get Your
Custom Quote.
Tell us the essentials and a TerraBoard specialist will follow up with pricing and sizing — usually within one business day.
No commitment — just a conversation
Shipments delivered with TerraBoard
We'll help you spec the right size
Litho or flexo printing matched to your brand standards.
Manufacturer-direct pricing
Wholesale discounts available for high-volume orders.
Not ready for a quote?
Request a Custom Quote
Premium Sustainable Packaging
Ship smarter.
Waste less.
Brand better.
TerraBoard is the manufacturer — so you get 100% recycled, custom-printed mailers shipped straight from our US factory. No middleman, no markup, no minimum order, no inventory delays.
17M+
shipments
100%
plastic-free
No
minimum order
Made in USA
Louisville, KY
Curbside Recyclable
100% plastic-free
No Minimums
Order 1 case or bulk
Fast Fulfillment
Built for daily ops
Custom Branding
Full or single color
Why Buy Direct
Most sustainable-mailer brands are distributors.
We're the factory.
When you buy from a reseller, you pay their markup and wait on their stock. TerraBoard makes every mailer in-house in Louisville, KY — so the price, the customization, and the timeline are all ours to control, and yours to benefit from.
Our Products
Engineered for versatility.
Choose the perfect mailer for your needs. From lightweight flat mailers to padded protection — all 100% recyclable.
most Popular
Flat Mailers
Rigid and tear-resistant. Perfect for apparel, documents, prints, and thin items. Clean exterior for labels or custom branding.
6x9"
9×12"
10×13"
12×15"
+5 more
most Popular
Expandable Mailers
Designed to protect soft goods, lifestyle products, and small-batch eCommerce shipments with sustainable cushioning.
7×10"
9×12"
10×13"
12×15"
Custom
Custom Branded
Your brand on every mailer.
Two Color
Single Color
Kraft
White
Standout, pre-designed mailers for brands that want a memorable unboxing without the cost of custom art. Pick a design, choose your size, ship it out. No design fees, no minimums.
Sustainability
From production to recycling.
We support a sustainable loop every step of the way. Brands switching to TerraBoard report measurable reductions in both carbon footprint and carrier fees.
17M+
Shipments delivered with TerraBoard
5–18%
Avg. reduction in monthly carrier fees
100%
Curbside recyclable & plastic-free
78%
Of shoppers say packaging influences reorder
The Difference
Not all mailers are created equal.
See how TerraBoard stacks up against traditional plastic mailers and standard padded envelopes.
| TerraBoard® | Plastic Poly Mailer | Standard Padded | |
|---|---|---|---|
| 100% Plastic-Free | ✓ | × | × |
| Curbside Recyclable | ✓ | × | |
| SB 54 / Regulation Compliant | ✓ | × | |
| Custom Branding Available | ✓ | × | |
| Rigid & Tear-Resistant | ✓ | × | |
| Made in USA | ✓ | × | × |
| No Minimum Order | ✓ |
Custom Orders
Tell us what you need.
Our team will prepare a fast custom quote tailored to your brand and product requirements — typically within one business day.
Fast Turnaround
Shipments delivered with TerraBoard
Brand-Matched Design
Litho or flexo printing matched to your brand standards.
Bulk Pricing
Wholesale discounts available for high-volume orders.
Request a Custom Quote
The Work
Branded mailers that do the talking
Real custom print on 100% recycled material — the unboxing your customers photograph and share.
most Popular
Flat Mailers
Rigid and tear-resistant. Perfect for apparel, documents, prints, and thin items. Clean exterior for labels or custom branding.
6x9"
9×12"
10×13"
12×15"
+5 more
most Popular
Expandable Mailers
Designed to protect soft goods, lifestyle products, and small-batch eCommerce shipments with sustainable cushioning.
7×10"
9×12"
10×13"
12×15"
Custom
Custom Branded
Your brand on every mailer.
Two Color
Single Color
Kraft
White