- T-shirt boxes are slim corrugated mailers, windowed cartons or two-piece boxes built for folded or rolled tees.
- CubitPack produces corrugated t-shirt mailers from 250 boxes, paperboard cartons from 1,000, and rigid boxes from 50.
- Orders ship in 10 to 14 business days (rush 4 to 5), and design help, dies, plates and US delivery are free.
- Pantone ink matching is guaranteed, and you approve a digital proof and 3D mockup before paying.
Custom T-Shirt Boxes
Custom t-shirt boxes printed with your logo and artwork for graphic streetwear tees, retail multipacks, subscription clubs and event merch. Order corrugated shirt mailers from 250 boxes, paperboard cartons from 1,000, or rigid gift boxes from 50. We make them in 10 to 14 business days (rush in 4 to 5) with free design help, no die charges, free shipping across all 50 states, and a 3D mockup before payment.
What are custom t-shirt boxes?
Custom t-shirt boxes are low-profile paperboard, corrugated or rigid containers engineered to hold single folded tees, rolled promotional shirts or multi-shirt packs while displaying your label's artwork inside and out. Unlike poly bags that crumple in transit, a shallow rigid-walled box keeps collar ribs flat, protects chest screenprints from cracking along sharp creases, and turns a basic cotton staple into a giftable package. Online streetwear brands and monthly shirt clubs favor roll-end tuck-front corrugated mailers that travel directly through USPS without an outer envelope, whereas retail stores use straight-tuck folding cartons with a die-cut feeler window so shoppers can touch the jersey knit. At CubitPack, custom t-shirt boxes start at 250 units for corrugated mailers, 1,000 units for folding cartons and 50 units for rigid boxes, made in 10 to 14 business days with free design help, no die charges and free shipping to all 50 states.
T-shirt boxes facts
- Minimum
- 250 mailers · 1,000 cartons · 50 rigid
- Turnaround
- 10–14 business days
- Rush
- 4–5 days, quoted
- Materials
- Corrugated, white card, kraft, rigid board, recycled
- Printing
- CMYK, Pantone, inside lid printing, white ink on kraft
- Finishes
- Matte, gloss, soft-touch, foil stamping, emboss, deboss, spot UV
- Add-ons
- Feeler windows, tissue paper, hang tabs, ribbons, stickers
- Shipping
- Free to all 50 states
- Proofs
- Free digital proof and 3D mockup before payment
Which t-shirt box style matches how I sell my tees?
| Box style | Best t-shirt use case | Mails without outer bag? | Retail display feature | Minimum order |
|---|---|---|---|---|
| Roll-end tuck-front mailer | DTC streetwear drops, subscription tee clubs and merch bundles | Yes, fluted corrugated | Full inside-lid print area | 250 boxes |
| Straight tuck end carton | Retail shelf undershirts, organic basics and 3-pack crew tees | Pack in shipping carton | Optional window or hang tab | 1,000 boxes |
| Two-piece pop-up shirt box | Department store gift tees, golf polos and resort shirts | Slip into poly mailer | Classic lift-off lid unboxing | 1,000 card / 50 rigid |
| Pillow box | Single rolled event tee, concert souvenir or boutique impulse item | Pack in outer mailer | Curved silhouette, optional handle | 1,000 boxes |
| Tray and sleeve box | Numbered artist collaborations and collector graphic tees | Pack in outer mailer | Sliding drawer reveal | 1,000 card / 50 rigid |
| Magnetic closure rigid box | VIP press kits, luxury mercerized cotton tees and sponsor gifts | Pack in outer carton | Reusable keepsake with magnets | 50 boxes |
Not sure which style fits?
Request a Quote →What size t-shirt box do I need?
We cut every t-shirt box to your exact inside length × width × height in inches with no die charges. Pick your fold style first (rolled, compact quarter-fold, or flat retail board fold) and add ¼ inch of finger clearance around the cotton stack. Whether you are comparing t-shirt packaging boxes, printed shirt mailer boxes, retail tee boxes with window, two piece t-shirt gift boxes or custom printed t shirt boxes, we size the template to your exact container.
| Inside size (in) | Typically fits | Popular style |
|---|---|---|
| 6.5 × 4.5 × 2 in | One tightly rolled lightweight ringspun tee or youth shirt | Pillow box or straight tuck carton |
| 9 × 6.5 × 1.5 in | One compact quarter-folded crew-neck or V-neck tee (4.5 to 5.5 oz fabric) | Window tuck carton or slim mailer |
| 10 × 8 × 2 in | One heavyweight boxy streetwear tee (6.5 to 8 oz cotton) with chest print visible | Roll-end tuck-front mailer |
| 11.5 × 8.5 × 2 in | One standard retail board-folded tee, polo shirt or long-sleeve graphic shirt | Two-piece shirt box or mailer |
| 12 × 10 × 3 in | A 3-pack of everyday tees, or two graphic shirts paired with a beanie or socks | Roll-end tuck-front mailer |
| 12 × 10 × 4.5 in | A 5-pack basics bundle or corporate welcome kit with tee, notebook and sticker pack | Corrugated mailer with optional divider |
Suggested inside size: 6.5 × 4.5 × 2 in
A starting point. Your account manager confirms the size with you before the proof.
Quote this size →Know your product's size? Work out the inside box size with our free box size calculator.
Have your inside dimensions ready? Request pricing across up to 3 quantities.
Request a Quote →How do I choose t-shirt boxes?
- Pick your shirt fold firstDecide between a compact 9 × 6.5 in fold, a 10 × 8 in chest-graphic fold, or an 11.5 × 8.5 in retail fold.
- Keep the box height shallowA 1.5 to 2 in depth holds one tee flat so the collar and screenprint cannot slide into wrinkles.
- Match board to how you sellUse corrugated mailers for direct USPS shipping and paperboard cartons for retail shelves or multipacks.
- Show off fabric or chest artAdd an open feeler window on retail cartons or fold the shirt so the chest graphic faces the open lid.
- Protect fresh screenprintsWrap puff ink, plastisol or discharge-printed tees in acid-free tissue paper so ink never rubs the board.
- Send artwork or an AI conceptUpload your vector logo, ask for free design help, or bring an AI graphic for a free dieline and 3D mockup.
What are t-shirt boxes made of?
Which finishes can t-shirt boxes have?
Which add-ons can I get?
T-shirt boxes specifications
| Spec | Options |
|---|---|
| Box styles | Roll-end mailers, straight tuck cartons, two-piece shirt boxes, pillow boxes, sleeve boxes, rigid boxes |
| Board options | Corrugated, white card / paperboard, kraft, rigid board, recycled |
| Board caliper & flute | Corrugated board, card (paperboard) or kraft board matched to parcel weight |
| Printing | Full-color CMYK, Pantone match guaranteed, inside printing, white ink on kraft |
| Finishes | Matte, gloss, soft-touch lamination, foil stamping, emboss, deboss, spot UV |
| Windows & cutouts | Open feeler cutouts or film window patching |
| Size range | Custom inside L × W × H to order; min/max dimensions |
| Minimum order | 250 mailers · 1,000 folding cartons · 50 rigid boxes; delivered within ±5% |
| Proofs & samples | Free digital proof and 3D mockup before payment; $50 sample kit available |
| Turnaround & shipping | 10–14 business days (rush 4–5 days); free shipping across all 50 states |
Ready to quote your t-shirt boxes? Compare up to 3 quantities with a free 3D mockup.
Request a Quote →How do clothing brands and merch teams use custom t-shirt boxes?
A heavyweight 280 GSM streetwear drop tee, a retail three-pack of undershirts and a corporate conference giveaway shirt need very different structures. Tell us how your shirts are folded and whether they mail direct or hang on store fixtures, and we configure the board and dieline around your workflow.
T-shirt boxes design ideas
Example designs with made-up brands. Your packaging is made to your design.
What are the most common custom t-shirt box mistakes?
Most t-shirt packaging problems come from using an overly deep box or letting fresh screenprints rub against unlined board. Check these five. When specifying t shirt boxes with logo, printed t shirt boxes, branded t shirt boxes, wholesale t shirt boxes and bulk custom t shirt boxes, avoid these common production mistakes
- Packing a single tee in a 4-inch deep box. The shirt slides to one end in transit and arrives rumpled.
- Folding across the middle of a thick plastisol or puff chest print, which leaves a permanent crease line in the graphic.
- Mailing a thin 18pt retail shirt carton through USPS without an outer poly mailer or corrugated overbox.
- Placing an unlaminated dark interior lid directly against a white cotton tee without tissue paper between them.
- Sizing the box from a Small tee sample and discovering that heavyweight XL and XXL shirts bow the front flap.
Chat with a designer now
Share your logo, a sketch or an AI image. We'll rebuild every element cleanly onto your box dieline and send a 3D mockup, free.
Made your design with AI?
Generated a concept in Google Gemini, ChatGPT, Claude or Midjourney? Send us your AI image: we rebuild every element onto your box dieline and show you a 3D mockup before you pay, free.Custom vs stock t-shirt boxes: which is better?
| Stock (plain) | Custom from CubitPack | |
|---|---|---|
| Depth for a single tee | Overly deep 3 to 4 in stock mailers where one shirt slides and wrinkles | Shallow 1.5 to 2 in depth matched to your exact shirt fold |
| Chest print presentation | Plain brown interior that hides your brand story | Full inside-lid print, size icons and care instructions |
| Minimum order | Fixed warehouse bundles in generic sizes | 250 mailers, 1,000 folding cartons, or 50 rigid boxes |
| Lead time | Unprinted boxes ship from stock | 10–14 business days to order, or 4–5 business days rush |
| Design & dielines | No structural or artwork help | Free design help, free custom dieline, proof and 3D mockup |
Get custom t-shirt boxes sized to your product, with a free 3D mockup before you pay.
Request a Quote →Are t-shirt boxes safe and sustainable?
Ink-rub protection for white tees
Matte, gloss or soft-touch lamination locks down dark box inks so they never transfer onto white cotton shirts.Unbleached kraft and recycled boards
Pair organic cotton or hemp tees with natural kraft or recycled paperboard and corrugated board.FSC paper and ISO 9001 production
FSC-certified paper stocks and ISO 9001 partner facility production are available on request.How do I order custom t-shirt boxes?
Tell us what you need
Size, quantities or AI conceptCompare volume pricing
Dedicated account managerApprove your proof
Digital proof + 3D mockupMade and shipped
Free to all 50 statesHow much do custom t-shirt boxes cost?
The price depends on four things, and every custom quote is free.
Fold footprint & depth
A compact 9 × 6.5 × 1.5 in box uses less board than an 11.5 × 8.5 × 2 in boxBoard & structure
Folding cartons cost less at 1,000+ units; corrugated mailers save outer shipping bagsRun quantity
Unit cost drops cleanly from 250 to 1,000, 2,500 and 5,000 boxesPrint coverage & extras
Two-sided printing, foil stamping, windows and soft-touch film add finishing stepsTo trim box cost and postage, fold single tees to a compact 9 × 6.5 × 1.5 in or 10 × 8 × 2 in footprint, and pack S through XXL shirts in one box size using a folding board. First orders get 10% off, we beat written US competitor quotes for identical specs, and quotes arrive in 5-7 minutes. Buyers ordering personalized t shirt boxes, custom size t shirt boxes, two-piece shirt box t shirt boxes or streetwear drops t shirt boxes can compare up to three quantities in one quote.
10% off your first order.
Request a Quote →What do I need to send for a quote?
- The product and how many you need
- The inside size, or what goes in it
- A style, or ask us to suggest one
- Your logo or artwork (an AI image is fine)
- Pantone codes, if you have them
- Delivery ZIP code and the date you need it
Can I see a sample first?
Sample kit
Board and finish swatches, sample boxes, labels and bags. Credited to your first order.Digital proof + 3D mockup
See it before you payPrinted sample
Of your own designHow does shipping work?
- Free shipping to all 50 states
- Worldwide with DDP prices: duties and taxes included
- Blind and split shipping
- Damaged in transit? We reprint the damaged units free
Why brands choose CubitPack
Dedicated specialist
One account manager from quote to deliveryPantone guaranteed
Clearly off? We reprintReprint or refund
If we get it wrong, you chooseBBB accredited
A US business you can checkT-shirt boxes questions
What size box do I need for a single t-shirt?
For a compact quarter-folded crew-neck or V-neck tee, 9 × 6.5 × 1.5 in is the most economical size. If you want the front chest graphic to show flat when the lid opens, use a 10 × 8 × 2 in or 11.5 × 8.5 × 2 in box.
What is the minimum order for custom t-shirt boxes?
Minimums follow the box construction: corrugated t-shirt mailer boxes start at 250 units, thin paperboard folding cartons start at 1,000 units, and rigid gift boxes start at 50 units. Small trial runs are also possible case by case through your account manager.
Can I mail a custom t-shirt box directly without an outer poly mailer?
Yes, if you choose a corrugated roll-end tuck-front mailer box. Its fluted walls and double-thick side panels are built for USPS, UPS and FedEx sorting. Simply seal the front flap with a tamper sticker or tape.
What size box fits a 3-pack or 5-pack of t-shirts?
A folded 3-pack of standard ringspun cotton tees fits neatly inside a 12 × 10 × 3 in box, or a 9.5 × 7 × 3 in retail carton when folded tightly. A 5-pack of tees usually requires a 12 × 10 × 4.5 in box.
Can I add a window so shoppers can see and touch the t-shirt fabric?
Yes. On retail t-shirt cartons, we can die-cut an open feeler window at no extra die cost so customers can feel the jersey weight, or patch a clear film window to keep dust off white shirts.
How do I use one box size for Small through XXL t-shirts?
Fold every shirt size around the same acrylic folding board, such as an 8 × 10 in or 8.5 × 11 in board. That gives Small through XXL shirts the same length and width, and a 2 inch depth handles an XXL tee.
How long does it take to produce custom printed t-shirt boxes?
Standard production takes 10 to 14 business days after you approve your proof and pay. If you have an upcoming merch drop, concert tour or conference date, rush production in 4 to 5 business days is quoted with your order.
Can you match the Pantone ink from my t-shirt screenprint on the box?
Yes. Give us the Pantone (PMS) color numbers your screenprinter used for your chest graphic or neck label. CubitPack guarantees Pantone color matching and reprints free if a printed Pantone shade is off from the approved spec.
Are there extra fees for custom sizes, cutting dies or printing plates?
Never. CubitPack includes custom dielines, cutting dies, printing plates, design help and shipping to all 50 states at no extra charge, whether you order a slim single-tee mailer or a windowed carton.
Can I see a 3D mockup or sample of my t-shirt box before production?
Every order includes a free 2D digital proof and 3D mockup before you pay. You can also order our $50 sample kit to inspect board thicknesses, or request a paid printed sample credited to your order.
Still have a question? Ask a packaging specialist.
Request a Quote →T-shirt boxes terms, explained
- Chest-graphic fold
- Folding sleeves behind the back so the front screenprint stays centered and flat
- Feeler window
- An unfilmed die-cut opening on a retail shirt carton that lets shoppers touch the fabric
- Roll-end tuck-front
- A self-locking corrugated mailer with dust flaps that ships without glue
- E-flute corrugated
- A slim, fine-fluted corrugated board that prints sharply while resisting parcel crushing
- Pillow box
- A curved one-piece paperboard box that pops open to hold a rolled t-shirt
- Inside-lid print
- Artwork, drop numbers or washing instructions printed on the interior face of the lid
More for your apparel packaging
Learn more
Get your t-shirt boxes price
One dedicated account manager prepares pricing across up to 3 quantities.
- Free design & AI-to-print studio + 3D mockup
- No die or plate charges · 4–5 day rush available
- Free shipping to all 50 states
- 10% off your first order
- Reprint or refund if we get it wrong
Every CubitPack policy on this page (minimums, turnaround, board options, finishes and guarantees) comes from our published product specifications and was verified by a packaging specialist. Shirt fold dimensions are benchmark starting sizes confirmed on your dieline before proofing. Spot something wrong? Tell us and we fix it. Tell us if something looks wrong.
Sources
What changed
- October 22, 2026: First published.
- October 22, 2026: Updated specifications, terminology, and verified source links.