Custom Mailers

With the launch of our updated Custom Box experience, order history from the previous platform is no longer available. Follow the appropriate steps below based on how you placed your original order:

If your original order was placed on the previous platform:

1. Click “Explore Options” and select your box style.
2. Enter your box information, then click "Design Online".
3. When prompted, log in or create a new User ID using your FedEx account credentials.
4. In the online design tool, click Text > Add Text.
5. In the text field, enter your previous order number to notify Customer Service that this is a reorder.
6. Add the design to your cart and complete your order.
7. After placing your order, Customer Service will email you a PDF proof for approval within 24 hours before your order goes into production.

Download step-by-step reorder instructions (PDF)

Note: If you no longer have access to your previous order number, please contact our support team at 980.215.0961 for assistance.

If you recently placed your previous order using your FedEx credentials:

1. Sign in to your FedEx account.
2. Click your name or avatar at the top of the page and select “My Orders.”
3. Locate the previous order containing the item(s) you'd like to reorder.
4. Click “Reorder” to add the item(s) to your cart.
5. Once you're done, proceed to checkout.

Custom mailer boxes are used to package and ship products securely while showcasing your brand. They’re ideal for subscription boxes, retail orders, promotional kits, and e-commerce packaging, helping businesses deliver a professional unboxing experience and improve brand recognition.

Yes. All FedEx Office custom mailer boxes are made from recyclable corrugated materials. You can choose from kraft, standard white, or premium white options, all of which support sustainable packaging.

Yes. You can print on both the exterior and interior of your box to include your logo, brand colors, or messaging. This option is ideal for businesses that want to create an engaging, on-brand unboxing experience for customers.

You can upload your own artwork or use customizable templates to add logos, colors, and text to your mailer box.

If you’d like professional assistance, FedEx Office offers Box Design Collaboration Services for an additional cost, providing 1:1 support from experienced graphic and structural designers. Depending on your project needs, our team can:

• Design or adjust artwork to fit your box layout and dimensions
• Refine graphics, colors, and fonts (including color matching)
• Add functional or branded design features for interior and exterior printing
• Provide a PDF or 3D interactive file of your final design concept

Minimums apply: ½ hour for graphic design and 1 hour for structural design.
This service helps ensure your mailer box design is print-ready, professional, and aligned with your brand before production.

While Ear Lock Mailers and Tuck Top Mailers can be closed without tape, we recommend using tape when shipping to prevent tampering and ensure secure delivery.

Yes, one-piece folder mailers require glue or tape to securely close them.

FedEx requires packages to be at least 7" x 4" x 2". If your box is smaller, it must be placed inside a larger box to meet the minimum size requirement.

For detailed design and print setup guidelines, including file preparation, font recommendations, and barcode requirements, visit our Custom Boxes FAQs.

Marketplace Sellers can support you in the product selection process through contact support.

No, discounts are not valid on Marketplace Seller orders. FedEx Office discount codes only apply to FedEx Office products. 

Yes. Orders fulfilled by 3rd party Marketplace Sellers are shipped from the seller’s facility and, thus, will incur a separate shipping charge from one shipped from FedEx Office.

Please visit our FAQs page here for more frequently asked questions about Marketplace Sellers.