Custom Mailers & Branded Packaging

How to choose

Start with the moment, not the material — that's the part of a packaging brief we enjoy most. If the box is the unboxing hero (PR seeding, premium gifting, brand launch), step into rigid greyboard construction with a magnetic close, soft-touch laminate and a foil or deboss finish. The weight in the hand is what makes the recipient slow down. If the box is a transit-plus-reveal (DTC e-commerce, subscription, staff kits), a printed corrugated mailer does the heavy lifting beautifully — full-colour exterior, one-colour interior print, and a tissue-paper layer to make the opening feel considered. Print method drives both cost and character. Flexo is the most economical way to carry a bold logo on corrugated; it's what you want for 1,000+ unit runs. Digital print is the hero for short-run, full-colour, photographic or variable-data packaging — agencies love it for campaign-specific SKUs and personalised mailers. Offset gives the sharpest CMYK on rigid-box wraps. Foil stamp, spot UV and blind deboss are the finishes that make a rigid box feel like a gift — use them sparingly, on one hero element, for the best effect. Material is where the sustainability story either lands or doesn't. FSC-certified kraft and recycled corrugated are our default substrates — they carry the eco narrative without needing a press release. For void fill we route agencies away from polybeads and toward honeycomb paper wrap, shredded kraft or rPET film. Acid-free tissue paper in a custom Pantone is the most cost-effective way to extend brand colour into the unboxing without re-engineering the box itself. On MOQ: printed corrugated mailers start at 100-250 units; rigid boxes from 250-500. Custom tissue paper and branded tape typically start at 500-1,000 because of print-cylinder economics. Stock-shape mailers with a printed sticker seal are the smart move for pilots under 100 — same unboxing impression, a fraction of the tooling. Finally, always prototype. Forty-eight hours for a stock sample; 7-10 days for a white-mock of your custom dieline with artwork applied. The creative director holds it, folds it, photographs it under the studio lights, and the final approval is easy. Fast can still feel thoughtful — that's the standard our agencies run with us.

Delivery across Australia

Delivered Australia-wide in 10-20 business days standard — Sydney, Melbourne, Brisbane, Perth, Adelaide, Hobart and Canberra daily. Express 5-10 day turnaround available on corrugated mailers and stock-shape rigid boxes for late briefs. Free shipping on orders over AU$500. We kit, split-ship to multiple venues, warehouses or home addresses, and run timed-release dispatch for launch windows at no extra handling — from our Sydney warehouse and Byron Bay head office.

Why Sense2

• ✦30 years of packaging briefs — trusted by Australian agencies, retailers, government departments, universities and independent fashion houses for considered unboxing that photographs beautifully
• ✦In-house design studio for dielines, mockups, 3D renders and pre-production samples — so your creative team can hold the weight and check the print register before artwork lock
• ✦thousands of products in the catalogue including stickers, tape, tissue, ribbon, hang tags, void fill and kitting inserts — one brief, one PM, one on-time delivery
• ✦Sustainability, done credibly — FSC paper, recycled kraft, soy-based inks, rPET void fill, lower-ink packaging and plastic-free options across the range

Frequently asked questions

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