Custom Rigid Mailers.

A standard rigid box was never built for parcel handling, so we use heavier greyboard, 2mm and up, and reinforce the corners. Rigid board dents permanently instead of flexing back like corrugated, and corners take most of the impact in a sorting hub. Fitted inserts keep the contents from shifting and striking the walls.

We transit-test the build before production, since rigid shows damage more visibly than a box made of flute.

Greyboard soaks up damp readily, and a wet core warps the whole box. We wrap rigid mailers in laminated or treated papers that shed moisture from rain, a damp porch or a humid truck.

An anti-scuff laminate on top protects the print from rub marks as parcels slide against each other on conveyors. Without it, the box can arrive looking handled, which defeats the point of paying for rigid.

A collapsible rigid mailer has crease lines built into the board, so it ships to you flat and is folded into shape at packing. Without that, you'd pay freight on empty boxes full of air, which makes the format hard to justify at any volume.

Once erected, it presents as a proper rigid box on the customer's doorstep, with the same wrap and corners as a fixed build.

We build these with a telescoping lid that lifts off the base, and a ribbon pull can be added so it comes away cleanly. The telescoping style gives the classic two-piece rigid look on opening, and a fitted lid over a reinforced base stays square in transit.

For shipping we'd add a branded seal across the join so the lid stays shut through the network. Drawer and slide-out styles aren't offered in this range.

Soft-touch lamination gives the premium hand, but in parcel networks we pair it with an anti-scuff coating so it arrives without rub marks. Foil stamping, embossing or debossing, and spot UV all work on the wrap paper.

CMYK and PMS print cover the artwork itself, and interior print gives the customer a reveal when the lid comes off. A custom insert can be printed or wrapped to match.

Two frequent sizes are 9 × 7 × 2.5 in and 11 × 9 × 3 in, both quoted as inside dimensions. Rigid board is thick, so the outside of the box is noticeably bigger than the inside. Give us the product size and we'll work out the rest.

The insert takes up room too, which is another reason to send a sample item if you can spare one.

Yes, rigid mailers start at just 30 units, far lower than most boxes we make. That suits launch kits, influencer sends and limited editions where the box is part of what the customer keeps.

A small first run also lets you see how the box handles your real shipping routes before committing to a larger order.

A sample can be ready in 5 to 7 business days, and it's the step we'd never skip on a rigid mailer. Ship it to yourself through the carrier you normally use and see how it arrives.

Production then runs 7 to 10 business days, or 5 to 7 on rush. We credit the sample fee toward the order and ship to any US address.