Rigid Mailers

Along its longest dimension — that is the axis sorting machinery bends. A mailer stiff across the short side and flexible along the long one will still arrive bent.

Only if boxes are arriving crushed. If they arrive intact with damaged contents, the product is moving inside and a heavier outer changes nothing. A fitted insert solves that case, usually at lower cost.

Yes, and for rigid mailers we prefer to specify both together. A cavity that holds the contents still often lets us drop a grade on the outer, so the pair can cost less than an over-specified box alone.

Because they are hand-assembled rather than machine-glued, and because the wrap, corner finish and interior lining are each separate operations. They also ship assembled rather than flat, which raises freight. The trade is a structure that feels substantially different in the hand.

Ones that read from arm’s length. Soft-touch lamination and deboss change how the whole pack reads; a small foil detail often does not survive the distance between shelf and eye. We quote each pass separately so you can judge.

Measure the product rather than the box currently in use. Most operations we quote are running at least one size too large with void fill compensating, and dropping a band saves on every parcel rigid mailers carry.

That is a brand decision, not a cost or protection one. For direct-to-consumer parcels where the customer opens it, print can be worth it. For business deliveries it usually is not.

We issue a dieline template sized to your product, prepress checks your artwork against it, and a proof comes back for sign-off. Nothing runs until you approve that proof, and mailer boxes then take 3 to 5 business days.

Yes. Once a first run is approved we hold the board, structure, dimensions, print method and finishes against your account, so a reorder references the same specification exactly rather than being re-derived. That includes the ink formulation, which is what keeps a brand colour consistent between runs rather than drifting a shade each time.

Recycled grades are available across most of the substrates we run for mailer boxes. Recycled content, kerbside recyclability and certified compostability are three different claims though, so tell us which one you intend to print.

A print-ready PDF or a vector file, with fonts outlined and any raster images at 300 dpi at final size. We supply the dieline to design onto, and prepress checks bleed, safe area and crease clearance before issuing a proof. The dieline we supply carries the crease positions, so keeping type clear of a crease is easier to solve at layout than at proof.

A flat 100 units on any format. Most mailer boxes in this range are quoted from 100 units upward because unit cost falls sharply above that, but the minimum exists so you can validate a structure first.